6-1

PART 6-1 PAGE PART 6-5 PAGE

GENERALTRANSMISSIONSERVICE . .6-1 FORD DESIGN FOUR-SPEED
TRANSMISSION. . . . . . . . ... .6-35
PART 6-2
MODEL2.77 THREE-SPEED PART 6-6
PART 6-3TRANSMISSION
., .6-10 OVERDRIVE TRANSMISSION . .6-45
PART 6-7
MODEL 3.03 THREE-SPEED SPECIFICATIONS 6-56
PART 6-4 TRANSMISSION , .6-16

DAGENHAM FOUR-SPEED
TRANSMISSION ,. ... .6-25

GENERAL TRANSMISSION SERVICE

Section Page Section Page

1 Diagnosis and Testing 6-1 Lubrication. . . . . . . . . . . . .6-8
2 Common Adjustments and Repairs 6-8 3 Cleaningand Inspection .. .6-8
Rear Seal Replacement 6-8 Cleaning. . . . . . . . . . . . . .. .6-8
Rear Bushing and Seal Replacement. . . . . . . . . . 6-8 Inspection
.. .6-9

D DIAGNOSIS AND TESTING

causesand corrective measuresare
The problems related to the trans- clutch, clutch linkage, steering col-
mission usually are: excessive umns and shift linkage. Before and listed in the order they should be
amount of noise, hard shifting ef- during the road test make sure that checked to eliminate all possibility
forts, transmission jumps out, of, gear,
, th e c I u t c h IS
' f unc t lomngproper
,', Iy th e of maladjustmentor faulty compo-
gears
shifted from
clash when transmission
one gear ratio
IS
to an-
",
shift linkage IS properly
"
adjusted, the
nents outside of the transmission
prior to any transmissionremoval
other, and lubricant leakage. steering column is properly aligned
and disassembly.If the transmission
The car should be road tested, if and, that the transmission is filled was removed, repaired and rein-
possible, to determine or confirm to the proper level with lubricant, stalled, make certain the clutch and
complaint. Under normal operating , , ,
conditions, a large percentage of , The f?llowlOgdla~no~lsproced~re all the gear shift linkage is adjusted
transmission complaints are due to IS compiled as a guide 10 correcting to specifications.Road test the ve-
maladjusted or faulty components problems related to manual transmis- hicle to be sure that the problemhas
outside of the transmission, such as, sions. Trouble symptoms, possible been completely corrected.

DIAGNOSIS GUIDE-TRANSMISSIONS
To eliminateall possibilityof mal- in the clutch and/or clutch linkage, ing, Group 5 (Driveshaft and
adjustments or faulty components refer to Clutch Diagnosisand Test- Clutch), of the shopmanual.

rnNTINIIFD ON NEXT PAGE

6-2 GROUP 6 - MANUALSHIFTTRANSMISSIONS

DIAGNOSIS GUIDE-TRANSMISSIONS (Continued)

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

RATTLE OR BUZZ IN No transmissionoverhaul should be

FLOOR SHIFT LEVER attemptedto correct this problem as
(Continued) it is often mistaken for a grating
noisein the transmission.
1. Loose nuts at transmissionle- 1. Adjust levers and shift rods to
vers and shift rods. If the nuts are proper crossover, torque nuts to
loose, check for bell-mouthing of specification. Replace bell-mouthed
slots. rods or levers.
2. Bent transmissionshift rods or 2. Replacebent rods or levers.
linkageinterference.
3. Lack of lubrication of shift 3. Clean and lubricate with Lithi-
linkage, trunnions and external shift um base grease (no Polethylene).
mechanism (floor shift).
4. Improperly locatedconsoleand 4. Install correctly.
excessiveboot compression.(floor
shift)
S. Grommets damaged allowing 5. Replacedefectiveparts. Install
hold down bolts and/or hold down correctly.
washersto ground out againstlever
(floor shift).
GEAR CLASH CLUTCH LINKAGE
1. Lack of clutch pedal reserve, 1. Adjust to specification.
free play and total travel.
2. Bottoming of clutch release 2. Grind opening in clutch hous-
arm in window of clutch housing. ing or releasearm to provide clear-
ance.
3. Bent or cracked equalizerbar. 3. Replacedefectiveparts.

SHIFT LINKAGE
1. Impropercrossover.
2. Loose nuts at transmissionle-
vers and shift rods. If the nuts are
loose, check for bell-mouthing of
slots.
3. Bent transmissionshift rods or
linkage interference.
4. Lack of lubrication of shift
linkage, trunnions and external shift
mechanism (floor shift).
1-2. Adjust levers and shift rods
to proper crossover,torque nuts to
specification. Replace bell-mouthed
rodsor levers.
3. Replacebent rods.
4. Clean and lubricate with Lith-
ium basegrease(no Polyethylene).

CLUTCH
1. Excessiveengineidle speed. 1. Adjust engineidle rpm.
2. Inadequate clutch pedal reserve 2. Adjust clutch linkage to speci-
resulting in excessivespin time. fication. Check for damaged input
shaft pilot bearingor excessiveclutch
disc runout-replace defectiveparts.
3. Incorrectpedalfree travel. 3. Adjust to specification.
4. Disc binding on transmission 4. Check for burrs on splines,re-
input shaft. placeif necessary.
5. Excessivediscrunout. 5-7-8. Replaceclutch disc.
6. Flywheel housing misalign- 6. Align to specification.
ment.
7. Oil or grease on clutch fac-
ings from:
A. Releasebearing
B. engine
C. releaselever
D. pilot bearing
E. transmission
CONTINUED ON NEXT PAGE
 PART 6-1 GENERALTRANSMISSIONSERVICE 6-3

DIAGNOSIS GUIDE-TRANSMISSIONS (Continued)

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

GEAR CLASH (Continued) 8. Damaged or contaminated
clutch lining.
TRANSMISSION
1. Forward Gear Clash 1. A-B-C-D-F -G Replace worn or
A. Weak or broken insert defective parts.
springs in the synchronizer assembly.
B. Worn blocking rings and/or
conesurfaces.
C. Broken blocking rings.
D. Excessiveoutput shaft end
play.
E. Shifter fork loose on shift E. Torque shifter fork set
rails. screws to specification.
F. Binding input shaft pilot
bearing (non-synchronized low gear
transmission only).
G. Worn shifter forks or sleeves.
2. Reverse Gear Clash (Allow ap- 2. A. Adjust clutch to specifica-
proximately three-four seconds after tion-See possible causes under
the clutch pedal has been depressed Clutch for gear clash trouble sym-
before shifting into reverse gear). toms.
A. If gear clash continues after
allowing proper time for the clutch
plate to stop, check the clutch ad-
justments to make sure that they are
within specifications.
B. Excessive engine idle speed. B. Adjust engine idler rpm.
C. Binding input shaft pilot CoD. Replace defective parts.
bearing.
D. Worn or damaged clutch
disc

HARD SHIFTING SHIFT LINKAGE

1. Impropercrossover. 1-2. Adjust levers and rods to
2. Loose nuts at transmissionle- proper crossover,torquenuts to spec-
vers and shift rods. If the nuts are ification. Replacebell-mouthedrods
loose, check for bell-mouthing of or levers.
slots.
3. Bent transmissionshift rods or 3. Replace bent rods or levers,
linkageinterference.
4. Lack of lubrication of shift 4. Clean and lubricate with Lith-
linkage, trunnions and external shift ium basegrease(no Polyethylene).
mechanism(floor shift).
s. Improperly locatedconsoleand 5. Install correctly
excessive boot compression (floor
shift).
STEERING COLUMNS
1. Improper column alignment. 1. Align column properly, replace
looseness,binding and worn surfaces. defective column parts and fasten
Make certain the toe plate at the toe plate to firewall securely.
base of the column is fastened se-
curely to the firewall.
2. Worn shift key or broken weld 2-3-4. Replace defective parts.
securing shift key to top or bottom
of shift tube.
3. Loose shift lever pin in die cast
selector lever hub.
4. Keyway in die cast selector le-
ver hub pounded out.
rnNTINllFn nN NEXT PAGE
DIAGNOSIS GUIDE-TRANSMISSIONS (Continued)
---~

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

HARD SHIFTING 5. Alignment of column to steer- 5. Align properly.

(Continued) ing gear pilot bushing.
6. Loose screws securing die cast- 6. Replacedefectiveparts. Tight-
ing to bottom of tube. Excessive ra- en screwssecurely.
dial movement in the column link-
age. (If the vehicle has high mile-
age or is subjected to hard use, even
though the crossover has been prop-
erly set, the column may have de-
teriorated to a point where proper
crossover engagement will not occur
due to excessiveradial movement in
the column linkage (lost motion).
7. Lack of lubrication at column 7. Clean and lubricate with Lith-
lower plate. ium basegrease(no Polyethylene).
CLUTCH LINKAGE
1. Loss of clutch pedal reserve, 1. Adjust to specification.
free play and total travel.

TRANSMISSION
1. Excessiveshift effort 1. A. Torque screwsto specifica-
A. Shift side cover loose or tion. Replacedamagedcover.
damaged (Dagenham, Warner Gear
four speed overdrive transmission
onlv), B-C-E. Replace worn or de-
B. Shift levers, shafts or forks fective parts.
worn or bent.
C. Synchronizerworn or bro-
ken.
D. Shift rail componentsnot D. Install correctly,replacede-
functioning properly. fective parts, if necessary.
E. VVorn shifter forks or
sleeves.
2. Sticking in Gear 2. A. Fill to bottom of filler plug
A. Low lubricant level. hole.
B. Corroded transmission le- B-D. Free-up and clean parts,
vers (shaft). replace if necessary.
C. Defective(tight) input shaft C-E. Re1Jlacedefective parts.
pilot bearing.
D. Stuck detent plug.
E. Burred or batteredteeth on
synchronizer sleeve and/or input
shaft.
F. Shifter fork loose on shift F. Torque shifter fork ~et
rails. screw to specification.
GEAR JUMPOUT SHIFT LINKAGE
1. Improper crossover. 1-2 Adjust levers and rods to
2. Loose nuts at transmissionle- proper crossover. Torque nuts to
vers and shift rods. If the nuts are specification. Replace bell-mouthed
loose, check for bell-mouthing of rods or levers.
slots.
3. Bent transmissionshift rods or 3. ~eplace bent rods or levers.
linkage interference.
4. Lack of lubrication of shift 4. Clean and lubricate with Lith-
linkage, trunnions and external shift ium base grease(no Polyethylene).
mechanism(floor shift).
5. Improperly locatedconsoleand 5. Install correctly,
excessive boot compression (floor
shift).
 PART 6-1 - GENERAL
DIAGNOSIS GUIDE-TRANSMISSIONS
TROUBLE SYMPTOMS
GEAR JUMPOUT
(Continued)
LOCKED IN GEAR
When a complaint of momen-
tary locknut is encountered in
transmissionswith non-synchro-
nized low - gear, determine
whether 0 r not a normal
"blockout" condition exists. If
a "blockout" condition does ex-
ist, the customer should be in-
formed that the transmission
TRANSMISSION
SERVICE 6-5
(Continued)
POSSIBLE CAUSES CORRECTION
STEERING COLUMNS
1. Improper column alignment 1. Align column properly, replace
looseness,binding and worn surfaces. defective column parts and fasten
Make certain the toe plate at the toe plate to firewall securely.
base of the column is fastened se-
curely to the firewall.
2. Alignment of column to steer- 2. Align properly.
ing gear pilot bushing.
3. Worn shift key or broken weld 3-4. Replacedefectiveparts.
securing shift key to top or bottom
of shift tube.
4. Keyway in die cast selector le-
ver hub pounded out.
5. Loose screws securing die cast- 5. Replace de f e c t i v e parts.
ing to bottom of tube. Excessive Tightenscrewssecurely.
radial movement in the column link-
age. (If the vehicle has high mile-
age or is subjected to hard use, even
though the crossover has been prop-
erly set, the column may have de-
teriorated to a point where proper
crossover engagement will not occur
due to excessiveradial movement in
the column linkage (lost motion).
TRANSMISSION
1. Transmission misaligned or 1. Align to specification. Torque
loo~e. transmission-to-flywheel housing bolts
and flywheel housing-to-engine bolts
to specifications.
2. Bent or worn shift fork, lever 2-3-5-6-7. Replace worn or de-
and/ or shaft. fective parts.
3. Worn input shaft pilot bearing.
4. End play in input shaft (bear- 4. Torque retainer bolts to speci-
ing retainer loose or broken, loose fication. Replaceworn or defective
or worn bearings on input and out- parts.
put shafts).
5. Detent springs broken.
6. Detent notches worn.
7. Worn clutch teeth on the re-
spective gear and/ or worn clutch
teeth on synchronizer sleeve.
8. Shift side cover loose or dam- 8. Torque screwsto specification.
aged (Dagenham and Warner Gear Replacedamagedcover.
four speed and overdrive transmis-
sion only).
9. Shifter forks loose on shift 9. Torque shifter fork set screw
rails. to specification.
SHIFT LINKAGE
1. Impropercrossover. 1-2. Adjust levers and rods to
2. Loose nuts at transmissionle- proper crossover. Torque nuts to
vers and shift rods. If the nuts are specification. Replace bell-mouthed
loose, check for bell-mouthing of rodsand levers.
slots.
3. Bent transmissionshift rods or 3. Replace bent rods or levers.
linkageinterference.
6-6
DIAGNOSIS GUIDE-TRANSMISSIONS
TROUBLE SYMPTOMS
LOCKEDIN GEAR
(Continued)
gears cannot be pulled into
mesh because of gear tooth to
tooth abutment which can be
eliminated by releasing and de-
pressing the clutch pedal again
(thus spinning the clutch disc).
This will re-index the drive and
driven gear teeth and allow the
gears to mesh.
NOISY IN FORWARD
SPEEDS
GROUP 6 MANUALSHIFTTRANSMISSIONS
(Continued)
POSSIBLE CAUSES CORRECTION
STEERING COLUMN CORRECTION
1. Tricking of shift linkage. Make 1-2.. Adjust column properly, re-
certain that when slowly shifting place defective parts and fasten toe
out of low gear, the low gear shift plate to firewall securely.
lever at the transmission is com-
pletely out of low gear detent prior
to the column shift lever dropping
through neutral crossover. If the
transmission shift lever is not com-
pletely out of low gear detent, the
shift interlock in the transmission
will prevent engagement of second
gear and a lockup condition occurs.
2. Improper column alignment,
looseness,binding and worn surfaces.
Make certain the toe plate at the
base of the column is fastened se-
curely to the firewall.
3. Alignment of column to steer- 3. Align properly.
ing gear pilot bushing.
4. Worn shift key or broken weld 4-5-6. Replace defective parts.
securing shift key to top or bottom
of shift tube.
5. Loose shift lever pin in die
cast selector lever hub.
6. Keyway in die cast selector le-
ver hub pounded out.
7. Loose screws securing die cast- 7. Replace defective parts. Tight-
ing to bottom of tube. Excessive ra- en screws securely. Clean and lubri-
dial movement in the column link- cate with Lithium base grease (no
age. (If the vehicle has high mileage Polyethylene).
or is subjected to hard use even
though the crossover has been prop-
erly set, the column may have de-
teriorated to a point where proper
crossover engagement will not occur
due to excessive radial movement in
the column linkage (lost motion).
Lack of lubrication at column lower
plate.
TRANSMISSION
1. Shift rail components not func- 1-3. Install correctly, replac de.
tioning properly. fectiveparts.
2. Gear seizure. 2. Replacedefectiveparts.
3. Synchronizer inse1'tsout of po-
sition.
1. Low lubricant level. 1. Fill to bottom of filler plug
hole.
2. Transmission misaligned 0r 2. Align to specification. Torque
loose. transmission-to-flywheel housing bolts
and flywheel housing-to-engine bolts
to specifications.
3. Input shaft bearings worn or 3--,-5-6-7. Replace worn or de-
damaged. fective parts.
4. Output shaft bearing worn or
damaged.
CONTINUED ON NEXT PAGE
 PART 6-1 - GENERAL
TRANSMISSION
SERVICE 6-7

DIAGNOSIS GUIDE-TRANSMISSIONS (Continued)

TROUBLE SYMPTOMS POSSIBLE CAUSES CORRECTION

~

NOISY IN FORWARD 5. Mainshaft gearsworn or dam-

SPEEDS(Continued) aged. (In any case of scored or
brokengears,the matinggearsshould
be checked).
6. Countershaft gear or bearings
worn or damaged.
7. Failure of the operatorto fully
engagethe gearson every shift be-
fore engagingthe clutch and apply-
ing enginepower.
Gear roll-over noise, inherent in
manual transmissions,is causedby
the constant mesh gears turning at
engineidle speed,while the clutch is
engagedand the transmissionin neu-
tral; and throwout bearing rub are
sometimesmistaken for mainshaft
bearingnoise.
Gear roll-over noisewill disappear
when the clutch is disengagedor
when the transmissionis engagedin
gear.Throwout bearingrub will dis-
appear when the clutch is engaged.
In the event that a bearingis defec-
tive, the noise is more pronounced
while engagedin gear under load or
coast than in neutral. When com-
plaintsof this natureare encountered,
it will be necessaryto road test the
vehicle to determineif bearingnoise
exists. Under no circumstances
should any transmissionrework be
attempted to eliminate gear roll-
over noise, or throwout bearing rub.

NOISY IN REVERSE 1. Reverse idler gear or shaft, 1-2. Replace worn or defective
worn or damaged. parts.
Z. Reversesliding gear worn or
hTnke-

LUBRICANT LEAKS 1. Excessivelubricant. 1. Drain to bottom of filler plug

hole.
2. Vent plugged. 2. Freeup.
3. Input shaft bearing retainer 3. Add sealerand torque retainer
looseor cracked,sealor gasketdam- bolts to specifications.Replace de-
aged. fective parts.
4. Worn or damaged extension 4-5-9. Replacedefectiveparts.
housingseal.
S. Worn shifter shaft seals. 5-6-7-8-10. Add sealer to bolts,
6. Shift side c 0 v e r bolts not and torque to specifications. Replace
sealed. (Dagenham and War n e r defective parts.
Gear four speedand overdrivetrans-
missiononly).
7. Shift side cover loose or gas-
ket damaged.(Dagenhamand War-
ner Gear four speedand overdrive
transmissiononly).
8. Extension housing b 0 Its not
sealed.
CONTINU~D ON N~XT PAG~
 6-8 GROUP 6 MANUALSHIFTTRANSMISSIONS

DIAGNOSIS GUIDE-TRANSMISSIONS (Continued)

I COMMON ADJUSTMENTS AND REPAIRS

REAR SEAL REPLACEMENT
1. Removethe driveshaft.
2. Remove the seal from the ex-
tension housingwith the tool shown
in Fig. 1.
3. Install the new sealin the exten-
sion housing with the tool shown in
Fig. 2.
4. Install the driveshaft.
REAR BUSHING AND SEAL
REPLACEMENT
1. Remove the driveshaft from
the car.
2. Insert the tool shownin Fig. 3
into the extension housing until it
gripsthe front sideof the bushing.
3. Turn the screw clockwiseuntil
the seal and the bushingare free of
the housing.
4. Drive a new bushing into the
extensionhousingwith the tool shown
in Fig. 4.

FIG. 1-Removing ExtensionHousingSeal

FIG. 4-lnstalling Extension

.~ Tool-T60K.7697.8 OR
7657.A AND Adapter

,
Tool -T64P .7657.A
T57L -7657 -A
HousingBushing
5. Install a new seal in the hous-
ing asshownin Fig. 2.
6. Install the driveshaft.
C1175-C C1173-C LUBRICATION
Lubrication level should be in line
FIG. 2-lnstalling Extension FIG. 3-Removing Extension with the bottom of filler hole right
HousingSeal HousingBushingand Seal side of transmission case.

~ CLEANING AND INSPECTION

CLEANING
1. Wash all parts, exceptthe ball
bearings,in a suitable cleaning sol-
vent. Brush or scrape all foreign
matter from the parts.Be careful not
~
to damageany partswith the scraper.
Dry all par t s with compressed
air.
2. Rotate the ball bearings in a
cleanin~solventuntil all lubricant is
removed.Hold the bearingassembly
to prevent it from rotating and dry
it with compressedair.
3. Lubricate the bearingswith ap-
Droved transmissionlubricant and
 PART
wrap them in a clean, lint-free cloth
or paper until ready for use.
INSPECTION
1. Inspect the transmission case
for being cracked, worn or damaged
bearing bores, damaged threads or
any other damage which could af-
fect the operation of the transmis-
sion.
2. Inspect the front face of the
case for small nicks or burrs that
could cause misalignment of the
transmission with the flywheel hous-
ing. Remove all small nicks or burrs
with a fine stone.
3. Replace a cover that is bent or
distorted. Make sure that the vent
hole in the cover is open.
4. Check the condition of the shift
levers, forks, shift rails and the lever
and shafts.
5. Examine the ball bearing races
for being cracked, worn or rough. In-
spect the balls for looseness, wear,
end play or other damage. Check the
bearings for looseness in the bores.
6-1 - GENERAL
TRANSMISSION
SERVICE
If any of these conditions exist, re-
place the bearings.
6. Replace roller bearings that are
broken, worn or rough.
7. Replace the countershaft (clus-
ter) gear if the teeth are chipped,
broken or worn. Replace the counter-
shaft if it is bent, scored or worn.
8. Replace the reverse idler gear
or sliding gear if the teeth are
chipped, worn or broken. Replace
the idler gear shaft if bent, worn or
scored.
9. Replace the input shaft and gear
if the splines are damaged or if the
teeth are chipped, worn or broken.
If the roller bearing surface in the
bore of the gear is worn or rough,
or if the cone surface is damaged,
replace the gear and the gear rollers.
10. Replace all other gears that
are chipped, broken or worn.
11. Check the synchronizer sleeves
for free movement on their hubs.
Make sure that the alignment marks
(etched marks) are properly in-
dexed.
6-9
12. Inspect the synchronizer block-
ing rings for widened index slots,
rounded clutch teeth and smooth in-
ternal surfaces (must have machined
grooves). With the blocker ring on
the cone, the distance between the
face of the blocker ring and the
clutch teeth on the gear must not
be less than 0.010 inches.
13. R e p I ace the speedometer
drive gear if the teeth are stripped
or damaged. Make certain to install
the correct size replacement gear.
14. Replace the output shaft if
there is any evidence of wear or if
any of the splines are damaged.
15. Inspect the bushing and the
seal in the extension housing. Re-
place them if they are worn or dam-
aged. The bushing and/ or seal should
be replaced after the extension hous-
ing has been installed on the trans-
mission.
16. Replace the seal in the input
shaft bearing retainer.
17. Replace the seals on the cam
and shafts.
6-10

MODEL 2.77 THREE-SPEED TRANSMISSION

Section Page Section Page

1 Description and Operation. . . . . . . . . . .6-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

4
Major
Repair
Operations
Description. . . . . . . . . . . . . . . . . . . . . .6-10 . . .. . .6-12

Operation , ,.,.,... . .6-10 Parts Repair or Replacement. . . . . . . . . . . ..6-12

2 In-Car Adjustmentsand Repairs. . . . . .6-11 Gear Shift Lever """"""" . . . . . .6-12

GearShift LinkageAdjustment- Cam and Shaft and Oil Seals. . . . . . . . . . ..6-13

Comet,Falcon,and Fairlane (6 and Input Shaft Bearing. . . . . . . . . . . . .6-14

GearShift LinkageAdjustment-
8 cylinder) 6-11 Output Shaft Bearing. . . . . . . . . . . . .6-14
Synchronizer. . . . . . . . . . . . . . . . . .,. . . . . . ..6-14

Mustang. . . . . . . . . . . . . . . . . . . . . 6-11 Countershaft Gear Bearings. . . . . ,, . . . . . . . .6-15

3 Removaland Installation. . . . . . . . . . 6-12 Front Bearing Retainer Seal. . . . . . . . . . .6-15

Removal. . . . . . . . . . . . . . . . . . . . . . . 6-12 Assembly

. . . . . .6-15

Installation. . . . . . . . . . . . . . . . . . . . . .6-12

- DESCRIPTION AND OPERATION

DESCRIPTION
The 2.77 C.D. three-speed trans-
mission is used in all models with a
170 or 200 C.W. engine. The des-
ignation 2.77 C.D. is the actual dis-
tance between the centerline of the
countershaft and the centerline of
the input shaft.
An identification plate (Fig. 1) is
attached to the upper right extension
housing attaching bolt.
A synchronizer is provided for
shifting to second and third speeds.
Shifts to first and reverse speeds are
accomplished with a sliding gear.
Ball bearings support the input
shaft and gear and the center of
the output shaft. Needle bearings
in the input shaft bore support the
front of the output shaft. The coun-
tershaft gear (cluster gear) also runs
on 2 rows of needle bearings. A
bronze bushing is used in the reverse
idler gear.
A bushing located at the rear of
the extension housing supports the
rear of the output shaft. The syn-
chronizer and the blocking rings are
the conventional tapered ring and
straight clutch gear type.
OPERATION
When first gear is selected, the
shift lever moves the first and reverse
sliding gear into mesh with the low
gear on the countershaft (cluster)
gear. Power flow is now from the in-
put gear, through the countershaft
gear to the first and reverse sliding
gear and out through the output
shaft.
When second gear is selected, the
shift lever moves the second and
third speed synchronizer sleeve rear-
CHANGE WITHIN TRANSMISSION AFFECTING
INTERCHANGEABILITY OF COMPONENT PARTS
C1345-B
ward to force the blocking ring coni-
cal surface against the matching cone
on the constant mesh intermedi-
ate gear located on the output shaft.
When the vehicle is moving, as when
shifting from low to a higher gear
ratio, the internal teeth of the syn-
chronizer sleeve and those on the
blocking ring will not index until the
intermediate gear is brought up or
down to the speed of the synchro-
nizer sleeve which is rotating at out-
put shaft speed.
The synchronizer sleeve with fur-
ther movement will slide over the
blocking ring and engage the clutch
teeth on the constant mesh inter-
mediate gear. Since the intermediate
gear is now locked to the output
shaft by means of the synchronizer
sleeve, power flow is from the input
shaft through the countershaft gear
to the constant mesh intermediate
gear to the ouput shaft.
Engagement of third speed is the
same as second except for ratio. In
third gear, the clutch teeth on the
input shaft are locked directly to the
output shaft by the second and third
speed synchronizer to provide a ratio
of 1:1.
Reverse gear is accomplished by
moving the first and reverse sliding
gear rearward to engage the reverse
idler gear. The drive is then from
the input gear, through the counter-
shaft gear, to and through the re-
verse idler gear to the first and re-
verse sliding gear which is splined to
the output shaft. The gears in this
 PART 6-2 MODEL 2.77 THREE-SPEED
TRANSMISSION 6-11

position will rotate the output shaft An interlock pin preventsselection tent balls are provided to hold the
in a reverse direction. of more than one gear at a time. De- selectedgear in the desiredposition.

IN-CAR ADJUSTMENTS AND REPAIRS

GEAR SHIFT LINKAGE

ADJUSTMENT-COMET,
FALCON, FAIRLANE

(6 AND 8 CYLINDER)

1. Placethe gearshift lever in the

neutral position.
2.. L~oosen the two gearshift rod

ldiustment nuts.

3. Insert a dealer fabricated spe.

cial tool in the slot provided in the

lower steeringcolumn. (SeeFig. 2

It may be necessaryto align the
levers to insert the tool.

4. Tighten the two 2earshift rod

adjustment nuts.
5. Remove the tool from the slot

in the steering column.

6. Start the en~ine and shift the

selector lever to each position to

make sure it operatesfreely

GEAR SHIFT LINKAGE

ADJUSTMENT-MUSTANG FIG. 2-Comet, Falcon and Fairlane Gearshift linkage Adjustment

1. Loosen the three shift linkage

adjustment nuts. Install a 1/4 inch

diameter alignment pin through the

control bracket and levers a~ ~hnwn

in Fig. 3.
2. Tighten the three linkage ad-
justment nuts and then remove the
alignmentpin.
3. Checkthe gearshift lever for a
smooth crossover. FIG. 3-Gearshift LinkaQeAdiustment-Mustana
6-12 GROUP6
REMOVAL AND INSTAllATION
REMOVAL
1. Raise the car on a hoist.
2. Remove the driveshaft. Insert
the extension housing seal installa-
tion tool, Fig. 2, Part 6-1, into the
opening of the extension housing to
prevent the lubricant from leaking
out.
3. Disconnect the speedometer ca-
ble from the extension housing, and
disconnect the gear shift rods from
the transmission shift levers.
On a Mustang, remove the three
bolts that attach the shift selector
assembly to the extension housing
and allow the assembly to hang by
the shift lever.
4. Remove the two nuts retaining
the transmission rear support to the
crossmember.
5. Place a transmission jack under
the flywheel housing and raise the
rear of the engine slightly.
6. Remove the two cotter pins,
nuts, and bolts that attach the cross-
member to the frame supports.
7. Disconnect the brake cable
from the equalizer lever. Separate
the lever from the crossmember.
8. Remove the crossmember from
MAJOR REPAIR OPERATIONS
DISASSEMBLY
1. Mount the transmission in a
holding fixture and drain the lubri-
cant.
2. Remove the transmission cover
and gasket.
3. Remove the extension housing
attaching bolts and remove the ex-
tension housing and gasket. To pre-
vent the output shaft from following
the housing (with the resultant loss
of needle bearings), tap the end of
the output shaft with a soft-faced
hammer while withdrawing the ex-
tension housing. See disassembly
(Fig. 4).
4. Remove the speedometer drive
gear snap ring, the gear, and drive
ball from the output shaft.
S. Remove the retainer for the
reverse idler shaft and countershaft
(Fig. 4).
6. Hold the countershaft gear with
a hook and using the tool (dummy
shaft) shown in Fig. 5, drive the
countershaft rearward out of the
countershaft gear and the transmis-
sion case. Then. carefully lower the
MANUALSHIFTTRANSMISSIONS
the frame supports and allow it to
hang by the brake cable.
9. Move the jack under the trans-
mission. Remove the four trans-
mission to flywheel housing mount-
ing bolts.
10. Move the transmission back
just far enough to clear the input
shaft and remove it from under the
car.
INSTALLATION
1. Install two guide pins in the
flywheel housing lower mounting
holes. Start the input shaft through
the release bearing. Align the output
shaft splines with the splines in the
clutch disc. Move the transmission
forward on to the guide pins. If the
transmission front bearing retainer
hangs-up on the release bearing hub,
move the clutch release lever to free
it.
2. Move the transmissionforward
until the input shaft is through the
clutch hub and entersthe pilot bear-
ing.
3. Install the two upper transmis-
sion to flywheel housing attaching
boltsand lockwashers.
countershaft gear and dummy shaft
to the bottom of the case.
7. After removing the input shaft
bearing retainer and gasket, remove
the input shaft assembly and front
synchronizer blocking ring from the
transmission case (Fig. 6).
8. Remove the synchronizer re-
taining snap ring from the output
shaft. Then, while holding the syn-
chronizer assembly together, pull the
output shaft out of the transmission
case. The intermediate gear and the
low and reverse gear will slide off the
output shaft as it is withdrawn from
the case. Lift the synchronizer assem-
bly, intermediate, low and reverse
sliding gears out of the case and re-
move the two shift forks. For ref-
erence in assembly, notice which
synchronizer hub end faces forward.
9. Using a soft drift, drive the re-
verse idler shaft out of the transmis-
sion case. Lift the reverse idler gear
and the countershaft gear out of the
case.
10. Remove the shift levers.
4. Removethe two guidepins and
install the two lower attachingbolts.
Torque all attaching bolts to speci-
fications.
5. Position the crossmemberto
the frame supports.Install the equal-
izer lever and brake cable.
6. Secure the transmission rear
support to the crossmember.Secure
the crossmemberto the frame sup-
ports and remove the transmission
jack.
7. Connectthe gearshift rods and
the speedometer cable.
On a Mustang, position the shift
selector assemblyto the extension
housing and install the attaching
bolts.
8. Removethe tool (Fig. 2, Part
6-1) from the rear of the extension
housing. Install the driveshaft, and
torque rear U-bolt nuts to specifica-
tion.
9. Fill the transmissionwith ap-
proved lubricant. Check the shifting
action of the transmission.
10. Adjust the clutch pedal total
travel, free travel and shift linkage
asrequired.
PARTS REPAIROR
REPLACEMENT
GEAR SHIFf LEVER
1. Removethe snapring from the
end of the selectorshaft with pointed
snapring pliers (Fig. 7).
2. Remove the flat washer and
spring.
3. After removing two bolts, pull
the retainer, selector levers, and
spacerfrom the shaft.
4. Drive the short selector lever
pin from the shaft with a large pin
punch.
5. Drive the long trunnion pin
from the shaft and remove the
trunnion and shaft.
6. If necessary to removethe studs
from the selectorlevers,removethe
cotter pins, flat washers,wave wash-
ers and studs.
7. Lubricate all mating friction
surfaceswith Lubriplate before as-
sembly.
8. Install the shaft in the bracket.
Position the trunnion and drive the
lon2 strai2ht pin through the trun-

FIG. 5-Removing or Installing
Countershaft
ninn and into the shaft until an eQual
length of the pin is exposed on both
sides of the shaft.
9. Drive the short pin into the
shaft until the pin is centered in the
shaft.
10. Install the levers and spacer
on the shaft as shown in Fig. 7.
11. Position the retainer and start
the bolts. Before tightening the bolts
be sure that the retainer is not inter-
fering with free movement of the
shaft. Tighten the boits.
12. Install the spring, flat washer
and snap ring.
13. Install the lever studs if they
were removed.
CAM AND SHAFTSAND OIL
SEALS
1. From the undersideof the case,
use a punch to drive out the tapered
pins that hold the cam and shaft as-
semblies in the case (Fig. 8). Use
hard, firm blows. Using a plastic
hammer, drive the intermediate and
high cam and shaft toward the inside
of the case and separate the detent
balls and spring from the plunger.
Push out the cam and shaft assem-
blies, and remove the plunger.
2. If required, the cam and shaft
oil seals in the case may be removed
with the tools shown in Fig. 9.
3. Install new seals in the case.
4. Install the reverse and low shift
cam and shaft through the case open-
ing. Assemble the spacer and spring
in the plunger. Apply grease to each
ball and position them in each end of
the plunger. Hold the plunger assem-
bly in position and install the inter-
mediate and high cam and shaft in
 ~.":)t ..i. 001-

~
, ~
OIL SEAL 100/-
159L-100-8
Cl168-B

FIG. 9-Removing (am and

Shaft Oil Seals

Fiber Block

OIL SLINGER"
INPUT SHAFf BEARING TooI-

1. Removethe snap ring securing ""c

BEARING. ~~~
T53T.4621-8

the input shaft bearing,and pressthe

input shaft out of the bearingand oil J
6-Removing Input Shaft slinger.

.""

C1170-A

j)
FIG. 10-lnstalling Input Shaft
'VER AS!
Bearing
7"'0
BOLT-
379818-S
GROMMET
379~19. S

~
+ ! 0' / SPRING
7208 PLUNGER
-
-
76125
@
':,..'~lc @ ~ TRUNNION - SNAP RING
,~ /
l.dJ r;;;. ~
7210
STRAIGHTPIN (LONG) - F LAT WASHER
97527.5
-
~ SUPPORT -
7416
379300.5
SPACER
- STRAIGHT
S
371681.5
SPRING-
7C307
7C383 , HAFT (SHORT) -
7Alll
SPACER -
SELECTOR SHAFT -
1 :"
, ~-=
7C383~
J ?;:)
7241 \

-- Js;;JJ
RETA)NER-

7~48 1
" SPRING-

~ 8- ~~ 7n7
FLAT WASHER- I:D:
44727-5 ,
I
COTTERPIN-
72016-5 ~ @Aft)
~
'- }}-
"'6
BOLT -
376444-5
SPRING WASHER -- SELECTOR LEVER-;
~
'SELEc-tOR LEV STUO-
35141'7
u,.u" ..'v
1?On 7285 7353 1...
("'581-A

7 -Gearshift Lever Disassembled-Typical

the case opening, allowing the balls 2. Press the input shaft bearing
to register in the cam detents. and oil slinger onto the input shaft
S. Align the cam and shaft grooves with the tool shown in Fig. 10, and
with the openings in the shaft bosses install the snapring on the shaft.
in the case, and install the retaining
pins. Check the cam action. Bent OUTPUT SHAFT BEARING
pins may restrict movement. 1. Removethe snap ring securing
~
 PART 6-2
3. Align the etch mark on the hub
with the etch mark on the sleeve.
Slip the hub and inserts into the
sleeve making sure that the etch
marksare aligned.
4. Securethe hub and inserts in
the sleevewith the two insert springs.
COUNTERSHAFf GEAR
BEARINGS
1. Removethe flat washers,dum-
my shaft, spacer,and roller bearings
from the countershaftgear.
2. Insert the spacer and dummy
shaft into the countershaft gear.
Position one flat washerat each end
of the spacer(Fig. 4). Coat the bore
in eachend of the countershaftwith
greaseand install twenty roller bear-
ings in eachend of the gear. Apply
a coating of grease to the other
two flat washersand the thrust wash-
ers and assembleat each end of the
countershaftgear. Note the position
of the tangson the thrust washers.
3. Placethe casein a vertical po-
sition. Align the gearbore and thrust
washerswith the bores in the case
and install the countershaft.
4. Place the case in a horizontal
position and check the countershaft
gear end play with a feeler gauge.
The end play should be 0.004-0.018
inch. If not within these limits, re-
place the thrust washers.
5. After establishingthe correct
end play, install the dummy shaft in
the countershaftgear and allow the
gear to remain at the bottom of the
caseuntil the output and input shafts
have been installed.
FRONT BEARING RETAINER
SEAL
1. Remove the input shaft seal
from the front bearing retainer as
shownin Fig. 12.
2. Install a new input shaft seal
as shownin Fig. 13.
ASSEMBLY
1. If the countershaft gear is not
already positioned in the bottom of
the case, do it at this time.
2. Position the reverse idler gear,
and insert the shaft (from the rear)
through the case just far enough to
hold the gear.
3. Using a light coat of grease,
MODEL 2.77 THREE-SPEED
TRANSMISSION
FIG. 12-Removing Input
Shaft Seal
assemble the needle bearings in the
input shaft. A thick film of grease
could plug the lubricant holes and
prevent lubrication to the bearings.
Install the front synchronizer block-
ing ring on the input shaft.
4. Install the shift forks on the
cam and shaft assemblies, with the
large fork on the intermediate and
high cam and shaft. The web of the
6-15
low and reverse fork must be to the
rear of the shaft center.
5. Start the output shaft through
the rear opening of the transmission
case. Place the low and reverse slid-
ing gear on the shaft, followed by the
intermediate gear. Tilt the output
shaft enough to allow the rear shift
fork to engage the sliding gear
groove.
6. With the longer hub end for-
ward slide the synchronizer assembly
on to the output shaft and engage
the synchronizer sleeve in the inter-
mediate and high shift fork.
7. Install the synchronizer hub
snap ring.
8. Position the input shaft and
synchronizer front blocking ring in
the front of the case seating the out-
put shaft pilot in the roller bearings
of the input gear.
9. Place a new gasket on the input
shaft bearing retainer. Install the in-
put shaft bearing retainer, using seal-
er on the bolts. Line up the drain
groove in the retainer with the oil
hole in the case.
10. Raise the countershaft gear to
align the dummy shaft with the
countershaft holes in the case. Start
the countershaft into the case from
the rear, and carefully drive the shaft
into position.
11. Install the reverse idler gear
shaft and the reverse idler shaft and
countershaft retainer.
12. Install the speedometer drive
gear and drive ball. Then secure the
gear with the snap ring.
13. Install a new gasket, and the
extension housing, using sealer on
the bolts. Torque the bolts to speci-
fication.
14. Install the shift levers.
15. If the extension housing bush-
ing and/or seal is to be replaced,
refer to Part 6-1, Section 2, for the
detailed instructions.
16. Pour lubricant over the en-
tire gear train while rotating the in-
put or output shaft. Install the trans-
mission case cover and gasket. Use
sealer on the bolts. The gasket vent
holes must be toward the rear, and
the cover vent hole must be toward
the front.
17. Check transmission operation
through. all shift positions.
6.16
Section
Description.
1
Description
and
2 In-Car Adjustment and Repairs .
Operation
Gear Shift Linkage Adjustment-
Comet. Falcon and Fairlane .
Gear Shift Linkage Adjustment-
Mustang. . . . . . . . . . . . . . . . .
3 Removal and Installation. . . . . .
Removal. ..............-
DESCRIPTION AND OPERATION
DESCRIPTION
The 3.03 REF
transmission (Fig.
cars having a 200 R.D. or 289 C.I.D.
engine. A 3.03 REG
mission is used on all cars equipped
with a 390 C.I.D.
1-3-Speed Transmission
tween the centerline of the counter-
shaft and the centerline of the in-
put shaft.
A transmission service identifica-
tion tag is located on the right side
of the case at the front. The first
line on the tag will show the trans-
mission model and service identifica-
tion code when required. The second
nation 3.03 is the actual distance be-
line will show the transmission serial
number.
MODEL 3.03 THREE-SPEED TRANSMISSION
Page Section Page
................ 6-16 Installation. . . . . . . . . . . . . . .6-19
Operation
6-16 4 Major Repair Operations. . . .6-19
6-16 Parts Repair or Replacement,
Disassembly
.6-19
6-17 .6-21
Shift Levers and Seals. . .
Gear Shift Lever ,6-21
6-17 .6-21
Synchronizers.
Input Shaft Bearing ........., 6-22
6-17 .6-22
6-18 Countershaft Gear Bearings .6-22
6-18 Assembly .6-23
This transmissionis of the fully shaft and gear and the center of the
Model three-speed synchronizedtype, with all gearsex- output shaft (Figs. 12 and 16). Roll-
1) is used on all cept the reversegear and sleevebe- er bearingsin tb,e input shaft bore
ing in constant mesh. All forward- and 19).
Model trans- speed changes are accomplished support the front of the output
with synchronizer sleeves(Fig. 2) shaft. The countershaftgear (cluster
engine. The desig- insteadof sliding gears.The synchro- gear) runs on two rows of roller
bearings.Two bronze bushingsare
used in the reverseidler gear (Fig.
11). A bushing located at the rear
of the extension housing supports
the rear of the output shaft.
Synchronizersand blocking rings
are the conventionaltaperedring and
straight clutch gear type (Figs. 17
The shift forks, shift rails, detent
mechanism, and related parts are
nizers enable quicke,. shifts, greatly provided in the transmission case
reduce gear clash and permit down-
(Fig. 9).
shifting, high to intermediate between
OPERATION
40-20 mph and from intermediate to
When the first-speed gear is se-
low below 20 mph.
lected, the shift lever moves the
The forward-speed gears are heli-
reverse gear and sleeve forward and
cal-cut and are in constant mesh
(Fig. 2). Gears used in the reverse forces the synchronizer blocking ring
gear train are spur-cut and are not conical surface against the matching
synchronized. cone on the constant mesh first gear
Ball bearings support the input located on the output shaft. If the
 PART 6-3 - MODEL 3.03 THREE-SPEED
TRANSMISSION 6-17

LOW AND REVERSE SLIDING SLEEVE AND GEAR with the countershaft(cluster) gear,
FIRST-SPEED GEAR, the power flow is from the input
OUTPUT SHAFT BEARING
gear, through the countershaftgear,
""
SECOND-SPEED GEAR

SYNCHRONIZER ""'" ffi; OUTPUT SHAFT to the constant mesh first gear,
SECOND
AND
HIGH
through the reversegear and sleeve
to the output shaft, and out the rear
of the transmission.

INPUT SHAFT AND GEAR

,
INPUT SHAFT BEARING
COUNTERSHAFT
COUNTERSHAFT CLUSTER GEAR
FIG. 2-Power Flow-3-SpeedTransmission
car is moving, the internal teeth of
the reverse gear and sleeve and
blocking ring will not index until
the constant mesh first
brought up or down to the speed of
the reverse gear and sleeve which is
rotating at output shaft speed.
=~ SPEEDOMETER
.
GEAR
Engagementof second and third
gearsis the sameas first exceptfor
ratio. In third gear, the input gear
,IDLER SHAFT
and shaft is locked directly to the
~
REVERSE IDLER GEAR
output shaft by the secondand third
'"
speedsynchronizerto provide a ratio
of 1:1.
Spur teeth are cut on the outside
of the reversegear and sleeve.The
reversegear and sleevelike the hub
are alwayslockedto the output shaft.
Reversegear is engagedby sliding
the reversegearand sleeveinto mesh
with the spur gear at the rear of the
idler gear. The drive is then from
the input gear, through the counter-
shaft gear, to and through the re-
verse idler gear to the output shaft
reversegear and sleeve.The gearsin
The reverse gear and sleeve has this position will rotate the output
internal splines that, with further shaft in a reversedirection.
movement, will slide over the block- A systemof interlocksand detents
gear is ing ring and engage external clutch in the transmissioncasepreventsthe
teeth on the constant mesh first gear. selectionof more than one gear at a
Since first gear is now locked to the time and helps to hold any gear in
output shaft and is always meshed the selectedposition.

IN-CAR ADJUSTMENTS AND REPAIRS

GEAR SHIFT LINKAGE the lower steering column. (See Fig.
3).
ADJUSTMENT-COMET,
It may be necessary to align the
FALCON, FAIRLANE
levers to insert the tool.
1. Place the gear shift lever in the
4. Tighten the two gearshift rod
neutral position. adjustment nuts.
2. Loosen the two gearshift rod S. Remove the tool from the slot
in the steering column.
adjustment nuts.
6. Start the engine and shift the
3. Insert a dealer fabricated selector lever to each position to
special tool in the slot provided in make sure it operates freely.
GEAR SHIFT LINKAGE
ADJUSTMENT-MUSTANG
1. Loosen the three shift linkage
adjustment nuts. Install a 1/4 inch
diameter alignment pin through the
control bracket and levers as shown
in Fig. 4.
2. Tighten the three linkage ad-
justment nuts and then remove the
alignment pin.
3. Check the gear shift lever for a
smooth crossover.
6-18 GROUP 6 MANUALSHIFTTRANSMISSIONS

T 1/2"

-L

FIG. 3-Comet, Falconand FairlaneGearshiftLinkageAdjustment

SHIFT CGlTROL AN ALIGNMENT TOOL CAN BE MADE FR~ 1/4"
BRACKET DIAMETER DRILL RDD BENT TO AN "L" SHAPE. THE
EXTENSIONSSHOULD BE 1 . 1/2" AND 3.3/4" FROM
THE ELBOW. SHORT END OF ALIGNMENT TOOL
SHOULD BE INSERTED INTO CONTROL BRACKET AND
/ LINKAGE HOLES UNTIL IT BOTTOMS.

" Alignment Tool

~
1/2'

/
3.3/4'

C1539-B

FIG. 4-Three-SpeedShift linkage Adjustment

REMOVAL AND INSTAllATION

REMOVAL 3. Slide the front of the drive- prevent the lubricant from leaking
l. Raisethe car on a hoist. shaft out of the extension housing out.
2. Disconnectthe driveshaft from and off the output shaft. Insert the 4. Remove the cap screw and lock
the rear V-joint fian!!e. tool shown in Fig. 2, Part 6-1, to washer that secures the speedometer
cable retainer to the extension hous-
ing. Pull the speedometer cable out
of the extension housing.
5. Remove the cotter pin, flat
washer, and spring washer that se-
cure the shift rods to the shift levers
on the transmission.
6. On a car equipped with a floor
mounted gear shift selector lever,
remove the three bolts that attach
the shift selector assembly to the
extension housing and allow the as-
sembly to hang by the shift lever.
7. Remove the two nuts securing
the transmission rear support to the
crossmember.
8. Raise the rear of the engine
enough to remove the weight from
the crossmember. Remove the two
nuts, washers and bolts securing the
crossmember to the frame supports.
Remove the crossmember.
9. Support the transmission with
a transmission jack and remove the
four flywheel housing-to-transmission
caseattaching bolts and lock washers.
10. Move the transmission and
jack rearward until the input shaft is
clear of the flywheel housing.
11. Remove the transmission from
under the car. Do not depress the
clutch pedal while the transmission
is removed.
- MAJOR REPAIR OPERATIONS
DISASSEMBLY
1. Mount the transmissionin a
holding fixture and drain the lubri-
cant.
2. Remove the nine cap screws
that attach the cover to the case.Re-
move the cover and the gasket(Fig.
5) from the case.
CO
FXTFN~I()N
. HruJSING
£.--~=
~ '!, .
GASKET""
- '~=:;~
PLUGS~ =_--~:;""
5-TransmissionCase and Related Parts-Typical
INSTALLATION
1. Make certain that the machined
surfaces of the transmission case and
the flywheel housing are free of dirt,
paint and burrs.
2. Install a guide pin in each
lower mounting bolt hole.
3. Start the input shaft through
the release bearing. Align the splines
on the input shaft with the splines
in the clutch disc. Move the trans-
mission forward on the guide pins
until the input shaft pilot enters the
bearing or bushing in the crankshaft.
If the transmission front bearing re-
tainer binds up on the clutch release
bearing hub, work the releasebearing
lever until the hub slides onto the
retainer. Install the two transmis-
sion-to-flywheel h 0 u sin g upper
mounting bolts and lock washers.
Remove the two guide pins and in-
stall the lower mounting bolts and
lock washers. Torque the four
mounting bolts to specifications.
4. Raise the rear of the engine
high enough to provide clearance for
installing the crossmember. Install
the two crossmember-to-frame sup-
port attaching bolts, washers, and
nuts. Do not tighten at this time.
S. Align the bolts in the trans-
mission rear support with the bolt
3. Remove the five cap screws
and lock washers that attach the
extensionhousing to the case. Re-
move the extensionand gasketfrom
the case.
4. Remove the four cap screws
and lock wahers that: attach the
front bearing retainer to the case.
~
CASE
"!7
.cd
r-
- !
,f . '
"'-'
ra ,"
"-'
'" -'-..1-
1
" ~
SERIALNUMBERPLATE
f
'/'
holes in the crossmember, then lower
the engine and remove the jack. In-
stall the two transmission rear sup-
port-to-crossmember washers and
nuts and torque to specifications.
Tighten the crossmember-to-frame
support nuts.
6. On a car equipped with a floor
mounted gear shift selector lever, po-
sition the shift selector assembly to
the extension housing and install the
attaching bolts.
7. Connect each shift rod to its
respective lever on the transmission
with a spring washer, flat washer,
and cotter pin.
8. Insert the speedometer cable
and driven gear in the extension
housing and secure with a cap screw
and lock washer.
9. Remove the tool shown in Fig.
2. Part 6-1, from the extension hous-
ing. Slide the front universal joint
yoke onto the output shaft and into
the extension housing. Connect the
rear universal joint to the axle pin-
ion flange and torque the nuts to
specifications.
10. Fill the transmission to the
proper level with the approved lubri-
cant and lower the car.
11. Adjust the clutch pedal free
travel and the shift linkage as re-
quired.
Remove the retainer and gasket from
the case.
5. Remove the lubricant filler
plug from the right side of the case.
Working through the plug opening,
drive the roll pin out of the case
and countershaft with a 1/4-inch
punch (Fig. 6).
6. Hold the countershaft gear with
FRONT
BEARINGRETAINER
,
-
C 1561.A
C 1583- A FIG. 6-Removing Countershaft
Roll Pin
 6-20 GROUP 6 - MANUALSHIFTTRANSMISSIONS

a hook and with the tool (dummy

shaft) shown in Fig. 7, push the
countershaftout the rear of the case.

CJ584.A

FIG. 7 -Removing Countershaft

The countershaft (cluster) gear
and thrust washers (Fig. 11) can be
lowered to the bottom of the case.
Remove the countershaft from the
rear of the case.
7. Remove the snap ring that se-
cures the speedometer drive gear sible, then rotate the first and reverse ring. It is necessaryto move the gear
on the shaft. Slide the speedometer shift fork upward, then lift it from forward to provide clearance when
drive gear off the output shaft. Re- the case.
move the speedometer drive gear removing the output shaft assembly
13. Move the second and third-
lock ball from the shaft. in HEG models. On HEF models,
speed shift fork to the second speed
8. Remove the snap ring that re- position to gain access to the set the input shaft and gear is removed
tains the output shaft bearing on screw. Remove the set screw from from the front of the case at this
the shaft. Remove the bearing from the fork. Rotate the shift rail 90° time.
the case and shaft as shown in Fig. 8 as shown in Fig. 10. 18. Rotate the second and third
9. Place both shift levers in the
neutral (center) position.

~
~--!
Clamp
Block
-
Remover

-- C1427-A
FIG. 8-Removing Output Shaft
Bearing
10. Remove the set screw (Fig.
9) that retains the detent springs
and plugs in the case. Remove the
detentspring and plug from the case.
11. Removethe set screwthat se-
cures the first and reverseshift fork
to the shift rail. Slide the first and
reverse shift rail out through the
rear of the case.
12. Slide the first and reverse
synchronizerforward as far as pos-
~
FIG. 1a-Rotating Secondand Third-Speed
Shift Rail
14. Lift the interlock plug (Fig.
9) from the case with a magnet.
15. Tap on the inner end of the
second and third shift rail to remove
the expansion plug (Fig. 9) from the
front of the case. Remove the shift
rail.
16. Remove the second and third
detent plug and spring from the de-
tent bore.
17. Pull the input gear and shaft
forward until the gear contacts the
case, and then remove the large snap
shift fork upward, and lift it from
the case.
19. Carefully lift the output shaft
assembly out through the top of the
case.
On HEG models, work the input
shaft bearings and gear back through
the bore in the case and out the top.
20. Driving from the front of the
case, remove the reverse idler gear
shaft from the case and then lift the
reverse idler gear and two thrust
washers (Fig. 11) from the case.

FIG. 11-Reverse Idler Shaft
and Gear-Disassembled
21. Remove the snap ring from
the front of the output shaft, then
slide the synchronizers and the sec-
ond speed gear (Fig. 12) off the
shaft.
equal length of the pin is exposed
on both sidesof the shaft.
9. Drive the short pin into the
shaft until the pin is centeredin the
shaft.
10. Install the levers and spacer
on the shaft as shown in Fig. 13.
11. Position the retainer and start
the bolts. Before tighteningthe bolts
be sure that the retainer is not inter-
fering .w:ith free movement of the
shaft'. Tighten the bolts.
12. Install the spring; flat washer
and snapring.
13. Install the lever studs if they
wereremoved.

FIG. 14-Shift Lever and

Shaft-Disassembled

the levers off the shafts. Slide each

lever and shaft out of the case. Dis-
card the "0" ring from each shaft.
2. Lubricate the new seals with
FIG. 1 2-0utput Shaft-Disassembled transmission lubricant and install
12. Remove the next snap ring SHIFT LEVERS AND SEALS them on the shafts.
and tabbed thrust washer from the 1. Remove the nut, lock washer 3. Install the lever and shafts in
output shaft, and then slide the first and fiat washer that secureseach the case.
gear and blocking ring off the shaft. shift lever (Fig. 14) to the lever and 4. Position a shift lever on each
23. Remove the next snap ring ~haft in the transmissioncase. Lift shaft and secure them with a flat
from the output shaft, and slide washer, lock washer and nut.
the reverse gear and sleeveoff the
shaft.
PARTS REPAIROR
~
REPLACEMENT
GEAR SHIFf LEVER
1. Removethe snapring from the
end of the selectorshaft with pointed
snapring pliers (Fig. 13).
2. Remove the flat washer and
spring.
3. After removing two bolts, pull
the retainer, selector levers, and
spacerfrom the shaft.
4. Drive the short selector lever
pin from the shaft with a large pin
punch.
5. Drive the long trunnion pin
from the shaft and remove the
trunnion and shaft.
6. If necessaryto removethe studs
from the selectorlevers,removethe
cotter pins, flat washers,wave wash-
ers and studs.
7. Lubricate all mating friction
surfaceswith Lubriplate before as-
sembly.
8. Install the shaft in the bracket.
Position the trunnion and drive the
long straight pin through the trun-
nion and into the shaft until an
6-22 GROUP 6 - MANUALSHIFTTRANSMISSIONS

INPUT SHAFf BEARING
1. Removethe snap ring securing
the input shaft bearing (Fig. 15),
and pressthe input shaft out of the
bearing.
ing sure that all three insert slots are
fully covered. With the alignment
marks on the hub and sleeve aligned,
start the hub into the sleeve. Place
the three inserts on top of the re-
taining spring and push the assembly
together. Install the remaining insert
spring, so that the spring ends cover
the same slots as does the other
spring. Do not stagger the springs.
Place a synchronizer blocking ring
on each end of the synchronizer
sleeve.

COUNTERSHAFT GEAR
BEARINGS
1. Removethe dummy shaft, 50
roller bearings,and the two bearing
retainer washersfrom the counter-
shaft gear (Fig. 18).
2. Coat the bore in each end of
the countershaftgear with grease.
2. Press the input shaft bearing
onto the input shaft with the tool
shown in Fig. 16 and install the snap
ring on the shaft.

C1025-8
FIG. 16-Replacing Input
Shaft Bearing

SYNCHRONIZERS ,NEEDLE BEARINGS(25 EACH

1. Push the synchronizer hub COUNTERSHAFT

from each synchronizersleeve.
2. Separatethe inserts and insert
springs from the hubs. Do not mix 1
the parts from the secondand third
speedsynchronizerwith the first and
reverse synchronizer (Figs. 17 and q
BEARING
19). BEA'RING -~ I
RETAINER
3. Install the rear insert spring
RETAINER ROLL PIN C1414-A
(Fig. 20) in the groove of the first
and reversesynchronizerhub. Make FIG. 1 8-Countershaft Gear-Disassembled
sure that the spring covers all insert
grooves.Start the hub in the sleeve
making sure that the alignment
marks are properly indexed.Position
the three inserts in the hub making
sure that the small end is over the
springand that the shoulderis on the
inside of the hub. Slide the sleeve
and reversegear onto the hub until
the detent is engaged. Install the
front insert spring in the hub to hold
the insertsagainstthe hub.
4. Install one insert spring (Fig.
19) into a grooveof the secondand
third speedsynchronizerhub, mak-
 PART 6-3
CORRECTREAR
SPRING INSTALLATI7
FIG. 20-First and Reverse Speed Synchronizer Insert Spring
Installation
3. Hold the dummy shaft in the
gear and install the 25 roller bear-
ings and a retainer washer in each
end of the gear.
4. Position the countershaft gear,
dummy shaft. and roller bearings in
the case.
5. Place the case in a vertical
position. Align the gear bore and the
thrust washers with the bores in the
case and install the countershaft.
6. Place the case in a horizontal
position and check the countershaft
gear end play with a feeler gauge.
The end play should be 0.004-0.018
inch. If not within these limits, re-
place the thrust washers.
7. After establishing the correct
end play, install the dummy shaft in
the countershaft gear and allow the
gear to remain at the bottom of the
case.
ASSEMBLY
1. Place countershaft gear in
proper position at bottom of case.
The countershaft gear will remain in
the bottom of the case until the out-
put and the input shafts have been
installed.
2. Coat the reverse idler gear
thrust surfaces in the case with a thin
film of lubricant and position the
two thrust washers (Fig. 11) in
place.
3. Position the reverse idler gear
and dummy shaft in place. Align the
gear bore and thrust washers with
the case bores and install the reverse
idler shaft.
4. Measure the reverse idler gear
end play with a feeler gauge. End
play should be 0.004-0.018 inch. If
the end play is not within limits, re-
place the thrust washers. If the end
MODEL 3.03 THREE-SPEED
TRANSMISSION
INCORRECT REAR
SPRING INSTAlLATIO7
play is within limits, leave the re-
verse idler gear installed.
5. Lubricate the output shaft
splines and machined surfaces with
transmission lubricant.
6. Slide the first and reverse gear
and sleeve (Fig. 12) onto the out-
put shaft with the teeth end of the
gear facing toward the rear of the
shaft. Secure it in place with the
snap ring.
7. Place the blocking ring on the
tapered machined surface of the first
gear.
8. Rotate the gear as necessaryto
engage the three notches in the
blocking ring with the synchronizer
inserts. Secure the first gear with the
thrust washer and snap ring.
9. Slide the blocking ring onto the
tapered machined surface of the
second gear. Slide the second gear
with blocking ring and the second
and third. gear synchronizer onto the
mainshaft. The tapered machined
surface of the second gear must be
toward the front of the shaft. Make
sure that the notches in the blocking
ring engage the synchronizer inserts.
Secure the synchronizer with a snap
ring.
10. Coat the bore of the input
shaft and gear with a thin film of
grease. A thick film of grease will
plug the lubricant holes and prevent
lubrication to the bearings. Install
the bearings (Fig. 15) in the bore.
If working on an HEG model
transmission, install the input gear
and bearing through the top of the
case and through the bore in the
front of the case. On HEF models,
the input shaft is installed through
the front of the case. Install the snap
ring in the bearing groove.
6-23
11. Position the output shaft as-
sembly in the case. Position the sec-
ond and third shift fork on the sec-
ond and third speed synchronizer.
12. Place a detent plug spring and
a plug in the case (Fig. 9). Place
the second and third speed synchro-
nizer in the second speed position
(toward rear of transmission). Align
the fork and install the second and
third speed shift rail. It will be nec-
essary to depress the detent plug to
enter the rail in the bore. Move the
rail inward until the detent plug en-
gages the forward notch (second
speed position).
13. Secure the fork to the shaft
with the set screw. Move the syn-
chronizer to the neutral position.
14. Install the interlock plug in
the case. If the second and third
shift rail is in the neutral position,
the top of the interlock will be slight-
ly lower than the surface of the first
and reverse shift rail bore.
15. Move the first and reverse
synchronizer forward to the first
speed position. Place the first and re-
verse shift fork in the groove of the
first and reverse synchronizer. Ro-
tate the fork into position and install
the first and reverse shift rail. Move
the rail inward until the center notch
(neutral) is aligned with the detent
bore. Secure the fork to the shaft
with the set screw. Install the re-
maining detent plug and spring. Se-
cure the detent spring with the
slotted head set screw. Turn the set
screw in until the head is flush to
0.020 inch below the top of the
case.
16. Install a new expansion plug
in the case.
17. Hold the input shaft and
blocking ring in position, and then
move the output shaft forward to
seat the pilot in the roller bearings
of the input gear.
18. Tap the input gear bearing
into place in the case while holding
the output shaft to prevent the roller
bearings from dropping. Install the
front bearing retainer and new gas-
ket, making sure that the oil return
slot is at the bottom of the case. In-
stall and torque the four attaching
screws.to 30-36 ft-ibs.
19. Install the large snap ring on
the rear bearing. Place the bearing
on the output shaft with the snap
ring end toward the rear of the
shaft. Press the bearing into place
with the tool shown in Fig. 21. Se-
cure the bearing to the shaft with a
snap ring.
6-24 GROUP 6 - MANUALSHIFTTRANSMISSIONS

FIG. 21-lnstalling Output
Shaft Rear Bearing
20. Hold the speedometerdrive
gear lock ball in the detent and
slide the speedometer drive gear into
place. Securethe gear with a snap
ring.
21. Place the transmissionin the
vertical position. Working through
the drain hole in the bottom of the
case,align the bore of the counter-
shaft gear and the thrust washers
with the bore of the case with a
screwdriver.
22. Working from the rear of the
case, push the dummy shaft out
of the countershaft gear with the
countershaft. Before the counter-
shaft is completely inserted in the
bore, make sure that the hole that
accommodatesthe roll pin is in
alignmentwith the hole in the case.
Push the countershaftinto place and
install the roll pin.
23. Coat a new extension hous-
ing gasket with sealer and position it
on the case.
24. Install lock washers on the
five attaching screws. Dip the threads
of the cap screws in sealer. Secure
the housing to the case and torque
the cap screws to 42-50 ft-ibs.
25. Install the filler and drain
plugs in the case. Make sure that the
magnetic plug is installed in the bot-
tom of the case.
26. Place the transmission in gear.
Pour lubricant over the entire gear
train while rotating the input or out-
put shaft.
27. Coat a new cover gasket (Fig.
5) with sealer. Secure the cover with
nine cap screws. Torque the screws
to 14-19 ft-ibs.
28. Check the operation of the
transmission in all of the gear posi-
tions.

DAGENHAM FOUR-SPEED TRANSMISSION
Section
1 Descriptionand Operation. . . . .
Description. . . . . . . . . . . . . . . . .
Operation. . . . . . . . . . . . . . . . . . .
2 In-Car Adjustmentand Repairs.
Gear Shift Linkage Adjustments
3 Removaland Installation. . . . . .
Removal. . . . . . . . . . . . . . . . . . .
Installation
4
Major
Repair
Operations
DESCRIPTION AND OPERATION
DESCRIPTION
1. The Dagenham four-speed
transmission (Fig. 1) is of the fully
synchronized type, with all gears ex-
cept the reverse sliding gear being In
constant mesh. All forward speed
changes are accomplished with syn-
chronizer sleeves (Fig. 2) instead of
sliding gears. The synchronizers will
enable quicker shifts, greatly reduce
1 -4.Sol!l!d Floor Shift Transmission
6-25
Page Section Page
. .. . .6-25 Parts Repair or Replacement
Disassembly
... .6-27
. " . .6-25 .., .6-28
..., .6-25 Gear Shift Lever. . . . . . . . . . .. .6-28
... . .6-26 Synchronizers. . . . . . . . . .
Shift Cover .., . .. .6-28
.. .. .6-26 ... .6-29
... . .6-26 Input Shaft Bearing. . . . . . ... .6-29
.6-26 Countershaft Gear Bearings . .. .6-29
. ... .6-27 Assembly
. . . .6-30
. ... .6-27
gear clash and permit down-shifting The shift pattern is shown on the
in all forward speeds. top of the gear shift lever knob. A
The shift linkage is mounted di- finger-operated release lever is pro-
rectly on the transmission extension vided on the shift lever (Fig. 3) to
housing (Fig. 1) and enters the driv- prevent the transmission from being
er's compartment through an open- accidentally shifted into reverse gear.
ing in the floor pan. A flexible rub- The forward speed gears are heli-
ber boot is provided to seal the cal-cut and are in constant mesh
driver's compartment from the ex- (Fig. 2). <fears used in the reverse
terior. gear train are spur-cut and are not
synchronized.
Ball bearing assemblies support
the input gear and the center of the
output shaft (Figs. 8 and 9). Roller
bearings in the input gear bore sup-
port the front of the output shaft.
The countershaft gear (cluster) also
runs on two rows of roller bearings.
A bronze bushing is used in the re-
verse idler gear (Fig. 17). The rear
of the output shaft is supported by
the driveshaft front yoke which in
turn runs on a steel-backed bushing
that is pressed into the extension
housing.
Synchronizers and blocking rings
are the conventional tapered ring
and straight clutch gear-type (Fig.
16).
A removable shift cover contains
the shift cams, forks, shafts, detents
and interlocks (Figs. 13 and 14).
A service identification tag is lo-
cated under the upper right hand ex-
tension to case attaching bolt. The
tag will show the transmission model
and service identification code when
required.
OPERATION
C 1586. A
When first gear is selected, the
shift lever and linkage move the first
and second shift fork and synchro-
6-26 GROUP 6
FIG. 2-Power Flow-4-SpeedTransmission
nizer sleeve toward the rear and
force the synchronizerblocking ring
conical surfaceagainstthe matching
cone on the output shaft first gear.
If the car is moving, the synchro-
nizer sleeve,blocking ring and first
gear clutch teeth will not index until
first gear is brought up or down to
the speed of the synchronizer and
the output shaft. The synchronizer
sleevehas internal splinesthat, with
IN-CAR ADJUSTMENT AND REPAIRS
GEAR SHIFT LINKAGE
ADJUSTMENT
To adjust the linkage, place the
shift lever in the neutral position and
raise the car on a hoist. Insert a 1/4-
inch fabricated alignment tool into
the alignment hole as shown in Fig.
3. If the rod will not enter, check for
bellied or bent shift rods. If the shift
rods are the correct shape, check for
loose lever lock nuts at the rod ends.
Reset the linkage by loosening the
three rod-retaining lock nuts and
moving the levers until the alignment
tool will enter the alignment holes.
Make sure the transmission shift le-
vers are in neutral and the reverse
shift lever is in the neutral detent
(Fig. 1). Install the shift rods and
torque the lock nuts to 15-20 ft-lbs.
Remove the alignment tool. Operate
the shift levers to make sure that the
detents are engaging. Lower the car
and check for smooth cross-over op-
eration.
REMOVAL AND INSTAllATION
REMOV AL
1. Raise the car on a hoist.
MANUALSHIFTTRANSMISSIONS
rear of the transmission.
Engagementof secondand third
gearsis the sameas first except for
ratio.
Fourth gear operation is accom-
plished in the samemanner as first,
second,and third, but the input gear
is locked directly to the output shaft
and the ratio is 1:1.
Spur teeth are cut on the outside
of the first and secondgear synchro-
nizer sleeve.The sleeveand hub are
always locked to the output shaft.
Reversegear is engagedby sliding
an idler gear into mesh with the
teeth on the first and second syn-
chronizer sleeveand the spur teeth
on the countershaftgear. The drive
further movement, will slide over is then from the input gear, through
the blocking ring and engage exter- the countershaft gear, through the
nal clutch teeth on the first gear. idler gear,to the output shaft reverse
Since first gear is now locked to the gear (synchronizersleeve) and the
output shaft and is always meshed output shaft, which is rotated in a
with the countershaft (cluster) gear, reversedirection.
the power flow is from the input A systemof interlocksand detents
gear, through the countershaft gear, in the shift cover preventsthe selec-
to the first gear on the output shaft, tion of more than one gear speedat
through the synchronizer sleeve and a time and helpsto hold any gear in
hub to the output shaft and out the the selectedposition.
AN ALIGNMENT TOOL CAN BE MADE FR~ 1/4"
DIAMETER DRILL RDD BENT TO AN "L" SHAPE. THE
EXTENSIONSSHOULD BE 1 - 1/2" AND 3 . 3/4" FROM
THE ELBOW. SHORT END OF ALIGNMENT TOOL
SHOULD BE INSERTED INTO CONTROL BRACKET AND
LINKAGE HOLES UNTIL IT BOTTOMS.
..., ~
- 1-
3.3i4'
,
--
SHIFT LINKAGE
ADJUSTMENT NUTS
C 1587- A
FIG. 3-Gear Floor Shift linkage Adjustment-Typical
1. Removethe starter cable from 3. Disconnect the driveshaft at
the starter and remove the starter. the pinion flange and tape the
 PART6-4
V-joint bearing races in place if the
joint does not have a strap spot
welded to it. Pull the driveshaft off
the transmission and insert the tool
shown in Fig. 2, Part 6-1 into the
seal and extension housing to pre-
vent lubricant leakage.
4. Remove the back-up lamp
switch (if so equipped) from the
shift linkage control bracket.
5. Remove the clip from the
equalizer bar at the clutch release
rod and remove the rod. Remove
the linkage return spring from the
releaselever.
6. Disconnect the parking brake
front cable from the equalizer bar.
Disconnect the speedometer cable
from the extension housing.
7. Loosen the shift linkage ad-
justing nuts shown in Fig. 3.
8. Remove the retaining clip, flat
washer and spring washer that se-
cures the shift rods to the shift le-
vers.
9. Remove the bolts that attach
the shift linkage control bracket to
the extension housing and allow the
assembly to hang by the shift lever.
10. Support the engine with a
transmission jack and remove the ex-
tension housing-to-engine rear sup-
port attaching nuts.
11. Raise the rear of the engine
and remove the transmission support
crossmember from the underbody.
MAJOR REPAIR OPERATIONS
DISASSEMBLY
1. Mount the transmission in a
holding fixture and drain the lubri-
cant.
2. Insert a reworked screwdriver
(Fig. 4) through the clutch release
lever and unhook the retainer that
securesthe clutch release lever to the
retainer bracket.
3. Remove the four attaching
bolts and the flywheel housing from
the transmission.
4. Remove the eight attaching
bolts and the shift cover from the
transmission.
S. Remove the three bolts and the
input gear bearing retainer from the
front of the transmission.
6. Remove the four bolts that se-
cure the extension housing and out-
put shaft bearing adapter to the
transmission case. In the event that
two long and two shorter bolts are
DAGENHAM FOUR-SPEED
TRANSMISSION
12. Support the transmissionand
remove the flywheel housing-to-en-
gine and engine rear plate-to-hous-
ing attachingbolts.
13. Move the transmission and
flywheel housing assembly toward
the rear until the transmissioninput
shaft splinesare clear of the clutch
assembly.Lower the transmission.
Do not depressthe clutch pedal
while the transmissionis removed.
INSTALLATION
1. Raise the transmission and
align the input shaft splines with
those in the clutch hub. Move the
transmission forward until the fly-
wheel housing is against the engine.
2. Install the flywheel housing-to-
engine and engine rear plate-to-hous-
ing attaching bolts. Torque the bolts
to specifications.
3. Position the transmission sup-
port crossmember to the underbody
and install the attaching bolts.
4. Lower the engine and trans-
mission and install the extension
housing-to-engine rear support at-
taching nuts. Torque the nuts to
specifications.
5. Position the shift linkage con-
trol bracket to the extension housing
and install the attaching bolts.
6. Secure each shift rod to its re-
spective lever with the spring wash-
er, flat washer and retaining pin.
used, the two longer bolts must be
installed in the upper right and low-
er left holes (viewed from the rear).
Remove the extension housing.
7. Working from the front of the
case, drive the countershaft, with a
drift, until it is just clear of the front
wall of the case. Hold the counter-
shaft gear with a hook and using the
tool shown in Fig. 5, push the coun-
tershaft out of the countershaft
(cluster) gear and transmission case.
Carefully lower the countershaft
gear to the bottom of the case.
8. Remove the output shaft as-
sembly from the rear of the case
(Fig. 6).
9. Remove the input gear and
bearing (Fig. 7) from the front of
the case.
10. Lift the countershaft gear as-
sembly out through the cover open-
ing of the case. Note the smallest
6.27
7. Connect the parking brake
front cable to the equalizer bar and
the speedometer cable to the exten-
sion housing.
8. Connect the clutch release rod
to the clutch equalizer shaft and to
the clutch release lever. Attach the
retaining clip and lever return spring.
9. Remove the tool from the ex-
tension housing and slide the drive-
shaft yoke onto the transmission out-
put shaft, being careful not to dam-
age the seal.
10. Be sure the pinion flange lo-
cating slots are clean, and then po-
sition the U-joint. Install the bolts
and torque them to specifications.
11. Install the back-up lamp
switch (if so equipped) on the shift
linkage control bracket.
12. Install the starter and cable.
13. Place both forward gear shift
levers and the reverse shift lever in
the neutral position and insert a 1/4
inch diameter alignment tool in the
shift linkage alignment hole (Fig. 3).
Adjust the linkage and tighten the
adjusting nuts. Remove the align-
ment tool. Adjust the clutch pedal
free travel as required.
14. Fill the transmission to the
proper level with specified lubricant.
15. Lower the car. Check the
shift crossover motion for full shift
engagement and smooth crossover
operation.
diameter thrust washer is positioned
between the rear of the countershaft
gear and the case and that the larg-
er diameter steel and bronze wash-
ers are at the front (Fig. 17).
11. Thread a 5/16-24bolt into the
rear of the reverse idler gear shaft
and pull the shaft using tools T50T-
7140-B (adapter) and T59L-I000-A
(puller). Remove the idler gear.
12. Remove the lock washer and
nut which retains the speedometer
drive gear and spacer from the rear
of the output shaft.
13. "Remove the speedometer gear
and drive ball. Remove the speed-
ometer gear spacer (Fig. 8).
14. Place the output shaft assem.
bly in an arbor press as shown in
Fig. 9 and press the bearing, adapt-
er, first gear, first and second specd
synchronizer assembly, and second
gear off the shaft. Do not lose the
 6-28 GROUP 6 - MANUALSHIFTTRANSMISSIONS

end of the selectorshaft with point-

ed snap ring pliers (Fig. 11).
2. Remove the flat washer and
" spring.
3. After removing two bolts, pull
~; the retainer, selector levers, and
RELEASE LEVER
RETAINER J! bracket from the shaft.
4. Drive the short selector lever
-.s: pin from the shaft with a large pin
punch.
GRIND Screwdriver RELEASE LEVER 5. Drive the long trunnion pin
BLADE AS SHOWN BRACKET
from the shaft and remove the
trunnion and shaft.
""'"
RELEASELEVER RETAINER HOOK
./ 6. If necessaryto remove the
studs from the selector levers, re-
~,'
~- J, move the cotter pins, flat washers,
wave washersand studs.
c
icY
7. Lubricate all mating friction
~
~ surfaceswith Lubriplate before as-
sembly.
8. Install the shaft in the bracket.
Position the trunnion and drive the
long straight pin through the trun-
~" nion and into the shaft until an equal
,#"-. .'" length of the pin is exposedon both
. sidesof the shaft.
9. Drive the short pin into the
shaft until the pin is centeredin the
CLUTCH shaft.
RELEASE
LEVER 10. Install the levers and the neu-
/ tral index bracket on the shaft as
shown in Fig. 11.
11. Position the retainer and start
the bolts. Before tightening the bolts
"< be sure that the retainer is not inter-
fering with free movement of the
~ shaft. Tighten the bolts.
C1390 -B 12. Install the spring, flat washer
and snap ring.
4-Removing or Installing Clutch ReleaseLever Retainer 13. Install the lever studs if they
wereremoved.

FIG. 5-Removing or Installing Countershaft
first speed gear sleeve retainer ball.
15. Wit~ snap rin~ pliers, remove
th~ snap rmg from m front of .the
thIrd and fourth-speed synchroDlzer
on the output shaft. Press the third
gear and the synchronizer off the
~
SHIFf COVER
1. Remove the levers from the
cam and shafts (Fig. 12).
2. Remove the roll pin from the
upper fork and shaft and removethe
shaft and forks.
3. Remove the reverse cam and
shaft.
4. Rotate the reverse fork and
shaft to disengagethe detent ball
and removethe fork and shaft (Fig.
13). Hold a cloth over the shaft cov-
er bossnearestto the fork to catch
the detent ball and spring when the
shaft clearsthe bosshole.
C1397-A 5. Removethe 1-2 and 3-4 shift
cam assemblies.Hold a cloth over
the interlock and cam assembliesto
shaft as shown in Fig. 10. catch the detent balls.
PARTS REPAIR OR 6. Push the interlock sleeve,
REPLACEMENT spring and remainingball out of the
cover.
GEAR SHIFf LEVER 7. Removethe 1-2 and 3-4-to-re-
1. Remove the snap ring from the verseinterlock pins from the reverse
 PART 6-4
COUNTERSHAFT GEAR IS RESTING ON BOTTOM OF CASE
(Dummy Shaft INSTAllED)
FIG. 6-Removing or InstallingOutput Shaft
FIG. 7 -Input Gear and Bearing-Disassembled
fork and shaft bossesin the cover.
8. If the sealsneed replacing, re-
move them with a screwdriver and
install them as shown in Fig. 14.
9. Place the 1-2 and 3-4-to-re-
verse interlock pins in the holes in
the reverse fork and shaft bosses
(Figs. 12 and 13).
10. Install the 3-4 shift cam in the
cover.
11. Install the parts of the 1-2
and 3-4 cam interlock, sleeve,ball,
spring and another ball, in that or-
der.
12. Hold the 3-4 cam in neutral
position and the 1-2 ball depressed
while the 1-2 cam is installedin the
cover.
13. Install the 1-2 and the 3-4
levers, washersand nuts.
14. Check the clearancebetween
the interlock. detent sleeveand the
DAGENHAM FOUR-SPEED
TRANSMISSION
,
(1392-8
1-2 and 3-4 shift cams in, and be-
tween, all shift positions. The sleeve
to cam clearance must be a mini-
mum of 0.0005 inch and a maxi-
mum of 0.010 inch. Service sleeves
are available in the following lengths
:c0.010 inch: 1.2875, 1.2905,
1.2935, 1.2965, 1.2995, and 1.3025.
15. With the 1-2 and 3-4 shift
cams in neutral and the 1-2 and 3-4-
to-reverse interlock pin resting on
the cams, install the reverse shaft de-
tent spring and ball and the reverse
fork and shaft.
16. Install the reverse shift cam
through the cover and into the
aligned fork and shaft. Install the re-
verse cam operating lever (washer
and nut loose).
17. Position the 1-2 and 3-4 forks
onto the shift cams and install the
fork shaft. Ali2n the shaft hole with
6-29
the one in the cover and install the
lock pin.
18. Check all shift positions for
freedom of movement, detent and
interlock action.
SYNCHRONIZERS
1. Before disassemblingthe syn-
chronizers,scribean alignmentmark
acrossthe hub and sleeveif they do
not havealignmentmarks.The align-
ment marks will permit the sleeves
and hubs to be assembledin their
original positions.
2. Removethe front and rear in-
sert springs from both synchronizer
assemblies(Fig. 15).
3. Slide the sleevesoff the hubs.
Removethe hub inserts (detents).
4. Place the long inserts (detents)
into the slots in the 1-2 synchronizer
hub and slide the combinationsleeve
and reversegear over it making sure
that the etch or scribemarks on the
hub and sleeve are aligned (Fig.
15). Snap the insert springs into
place. The tab on each spring must
set into the undersideof an insert.
S. Position the short inserts (de-
tents) into the slots in the 3-4 syn-
chronizer hub and slide the clutch
sleeveover it making sure that the
etch or scribe marks are aligned.In-
stall the insert springs in the same
manneras with the 1-2 synchronizer.
INPUT SHAFT BEARING
1. If the input shaft anc;i gear
bearing needs replacing, remove it
as shown in Fig. 16.
2. Pressthe bearing onto the in-
put shaft with the outer race snap
ring groove toward the front (Fig.
16).
3. Install the snap rings on the
bearing outer race and on the gear
shaft with snap ring pliers.
COUNTERSHAFfGEAR
BEARINGS
1. Remove the thrust washers
from each end of the countershaft
gear (Fig. 17).
2. Remove the dummy shaft from
the gear.
3. Remove the two washers and
22 roller bearings from each end of
the gear. Coat the bore in each end
of the countershaft with grease.
4. Place the tool (dummy shaft)
shown in Fig. 5 in the countershaft
(cluster) gear. Starting on either
end, drop a steel washer (Fig. 17)
over the tool and into the gear. In-
stall 22 roller bearings into the gear.
Lay another steel washer on the ends
 of the bearings and the thrust wash-
ers that were previously selected.
S. Repeat the above operation for
the other end of the gear. Do not
lose the bearings and washers in the
initially assembled end when invert-
ing the gear to assemblethe opposite
end.

ASSEMBLY
1. Place the secondgear on the
rear of the output shaft with the
-
INSTALLATION REMOVAL
C1400-8
clutch teeth and tapered synchro-
nizer end toward the rear. Install a
blocking ring with the clutch teeth
emoving and Installing Output Shaft Bearing toward the front (Fig. 8).
 PART 6-4
\ "
2 AND
3 AND 4 SHIFTERFORK
/ FORK GUIDE
REVERSE SHIFTER SHAFT AND
~ DETENTBALL AND SPRING
~.:y:
,..
./'
RETAINING PLUNGERS
D""
3 AND 4 CAM/"
AND SHAFT
,
INTERLOCK AND DETENT
BALLS AND SPRING
3 AND
FIG. 12-Gear Shift (over Disassembled
2. Install the first and second syn-
chronizer and reverse gear assembly
on the rear of the output shaft with
the shift fork groove toward the
rear. Be sure the second-speedblock-
ing ring is not cocked on the gear
and that the three index slots align
with the synchronizer inserts (de-
tents).
3. Install the first-speed blocking
ring with the clutch teeth to the rear
and the slots engaging the synchro-
nizer inserts (detents). Pack grease
into the ball pocket on output shaft
then insert the first-speed gear sleeve
retainer ball. See (Fig. 8).
4. With taper and clutch teeth to
front, and the sleeve (bushing)
shoulder to the rear, slide the first
gear and sleeve onto the output shaft
and align the slot on the I.D. of the
first-speed gear sleeve over the ball.
S. Assemble the output shaft ball
bearing into the recessin the bearing
adapter. Position the adapter and
bearing on the rear of the output
~
DAGENHAM FOUR-SPEED
TRANSMISSION
3 SHIFTER FORK
FORK
REVERSESHIFTERSHAFT
ANO 2 CAM AND SHAFT
~,.s, CAM AND SHAFT
REVERSE LEVER
) J
&.
~ 14. Using a light film of grease,
\9>
r;;:.,
1 AND'2 LEVER.
'-"'/4
LEVER
@ gearin the casefront bore. Placethe
(9 C 1588- A
shaft with the adapter forward. Hold
the first gear and sleeve (bushing)
forward and place the assembly in a
press with the tool resting against
the rear of the bearing inner race.
Press the bearing until .it is seated
firmly against the first gear sleeve
(bushing).
6. Place the spacer, speedometer
gear drive ball, speedometer gear
(shoulder to rear), lock washer (tab
into speedometer gear), and nut on
the output shaft (Fig. 8). Torque the
nut to 80 ft-ibs to insure axial loca-
tion of the synchronizer hub, first
speed gear sleeve, rear mainshaft
bearing, spacer and speedometer
drive gear on the output shaft.
Loosen the locknut and retorque to
25 ft.-lbs. Bend the washer over a
flat on the nut.
7. Set the third-speed gear on the
front of the output shaft with the
clutch teeth toward the front. Place
the blocking ring on the gear.
8. Install the 3-4 synchronizer
6-31
with the wide thrust surface of the
hub toward the rear. Align the
blocking ring slots with the synchro-
nizer inserts (detents).The hub to
shaft spline fit may require a slight
press to assemble.
9. Using snap ring pliers, install
the snap ring in its groove on the
front of the output shaft.
10. Position the countershaft
gear, dummy shaft, and roller bear-
ings in the case.
11. Place the case in a vertical
position.Align the gearbore and the
thrust washerswith the boresin the
case and install the countershaft.
12. Place the casein a horizontal
position and check the countershaft
gear end play with a feeler gauge.
The end play should be 0.004-0.018
inch. If not within these limits, re-
place the thrust washers.
13. After establishingthe correct
end play, install the dummy shaft in
the countershaftgear and allow the
gear to remain at the bottom of the
caseuntil the output and input shafts
have beeninstalled.
install roller bearingsin the bore of
the input shaft and gear.A thick film
of greasecould plug the lubricant
holes and restrict lubrication to the
bearings.
15. Install the input shaft and
fourth gear blocking ring on the rear
of the input gear with the clutch
teeth forward.
16. Enter the output shaft assem-
bly through the rear of the caseand
guide the output shaft front pilot
into the input gearbore and bearings
(Fig. 7). Be sure the fourth gear
synchronizerblocking ring slots in-
dex with the inserts(detents)on the
3-4 synchronizer.
17. Raise the countershaft (clus-
ter) gear and thrust washers until
the countershaft can be inserted
from the rear of the case into the
gear and bearings.The shaft should
push through, easily displacing the
tool. Push on the shaft until it con-
tacts the front of the case(Fig. 5).
Position the flat on the rear of the
countershaftin a horizontal plane so
it will align with the slot in the ex-
tension housing. Tap the shaft into
place.
18. Install the reverseidler gear
with the fork groovetoward the rear
and the idler shaft flat horizontaland
parallel with the countershaftflat.
19. Position a new extension
housing gasket on the rear of the
case,using a non-drying sealer.
6-32 GROUP 6 - MANUALSHIFTTRANSMISSIONS

case, bearing and adapter before

torquing the bolts. If two long and
two short bolts are used, install the
two long bolts in the upper right and
lower left holes.
21. If the input gear bearing re-
tainer seal needsreplacing, refer to
Fig. 19. Install the new bearing re-
tainer gasket,using sealer.Install the
bearing retainer with the drain slot
facing downward. Apply sealer to
the bolts and torque to specifications.
22. Place the 1-2 and 3-4 syn-
chronizer in neutral and the reverse
idler gear in reverse (forward) po-
sition. Set the reverseshift lever in
the reverse position. Install a new
shift cover gasketon the case,using
sealer. Install the shift cover. Use
sealeron the bolts and torque them
to specifications.
23. Install the flywheel housing.
Use sealeron the retaining bolts and
torque them to specifications.
24. Install the clutch releasebear-
ing on the clutch releaselever. Posi-
tion the release lever through the
housingfrom inside the housingand
clip the lever retainer onto its hook
as shown in Fig. 4.

FIG. 13-Transmission Shift MechanismDetails

SEALS C1423-A

FIG. 14--lnstalling (am and Shaft Seals

20. Install the extensionhousing. (Fig. 18). Using sealer, install the
Align the dowel in the housingwith extensionhousing bolts. Be sure the
the hole in the rear bearing adapter housing is seated squarely on the
 PART 6-4 - DAGEN
HAM FOUR-SPEED
TRANSMISSION 6-33

FIG. 1 5-SynchronizersDisassembled

~ _c_- -""""""'--
REMOVAL INSTALLATION C1403-B

FIG. 16-Removing and Installing Input Gear Bearing

6-34 GROUP 6 - MANUALSHIFTTRANSMISSIONS

FIG. 19-Removing Input

Shaft Bearing Retainer Seal-
Typical

1 7 -Countershaft and Idler Gear Disassembled

1 8-Extension HousingInstallation
 6-35

FORD DESIGN FOUR-SPEED TRANSMISSION

Section Page Section Page

1 Description and Operation. . . . .6-35 Parts Repair or Replacement. .. .6-39
Description. . . . . . . . . . . . . . . . .6-35 Gear Shift Lever. . . . . . . . . , .. .6-39
Operation. . . . . . . . . . . . . . . . . . .6-35 Cam and Shaft Seals. . . . . . , .. .6-40
2 In-Car Adjustment and Repairs .6-36 Input Shaft Bearing. . . . . . .. .6-40
3 Removal and Installation. . . . . .6-36 Synchronizers.. . . . . . . . . . . ., .6-41
Shift
Linkage
Adjustment
.6-37 CountershaftGear Bearings . . .6-41
Removal. . . . . . . . . . . . . . . . . . .6-37 ReverseIdler Gear Bearings . . .6-41
4 Major Repair Operations. . . . .
Installation ...,
.6-37 Input Shaft Seal. ......... .. .6-41
.6-38 Assembly .. .6-41
Disassembly
.6-38

DESCRIPTION AND OPERATION

DESCRIPTION
The Ford designed 4-speed trans-
mission (Fig. 1) is of the fully syn-
chronized type with all gears except
the reverse sliding gear being in
constant mesh. All forward-speed
changes are accomplished with syn-
chronizer sleeves. The synchronizers
will enable quicker shifts, greatly re-
duce gear clash, and permit down-
shifting into any forward-speed gear
while the car is moving.
The shift linkage is mounted di-
rectlv on the transmission extension
housing (Fig. 1) and enters the driv-
er's compartment through an open-
ing in the floor pan. A flexible rub-
ber dust boot (Fig. 3) is provided to
seal the driver's compartment from
the exterior.
The shift pattern is shown on the
top of the gear shift lever knob. A
finger-operated release lever is pro-
vided on the shift lever to prevent
the transmission from being acciden-
tally shifted into reverse gear. All
forward-speed gears in the transmis-
sion are helical-type, however, the
reverse sliding gear and the exterior
of the first- and second-speed syn-
chronizer sleeve are spur-type gears.
The specifications of this section
Part 6-6 lists the transmission model
numbers and vehicles in which they
are used.
A transmission service identifica-
tion tag is located on the right side
of the case at the front. The first line
on the tag will show the transmission
model and service identification code
when required. The second line will
show the transmission serial number.
The four-speed transmission will
be designated by the numeral 5 on
the vehicle warranty plate.

OPERATION
In first-speed (Figure 2), the first-
and second-speedsynchronizer sleeve
is moved rearward by the shift fork.
The sleeve engages the first-speed
blocking ring, which acts as a cone
clutch applied to the free-wheeling
first-speed gear. This action speeds
up or slows down the first-speed gear
to match the speed of the output
shaft. Further movement of the
sleeve locks the first-and-second-
speed synchronizer hub to the first-
speed gear by means of internal
splines. On engagementof the clutch,
power flows through the input shaft
and gear to the meshed countershaft
gear and thence to the first-speed
gear. This gear transmits the power
through the locked synchronizer hub
to the transmission output shaft. All
the other forward-speed gears are in
-Four-Speed Transmission idler motion, as they are all <;triven
6-36 GROUP 6 - MANUALSHIFTTRANSMISSIONS

SECOND SPEED
by the countershaft (cluster) gear,
G~AR but they do not transmit power be-
causethey are not locked to the out-
put shaft. All the forward-speed
shifts are made in the samemanner
as the first-speedshift, due to the
constant-mesh features.

Reverse gear is engaged by mov-

ing the reverse sliding gear forward
on the reverse idler gear until it
mesheswith the external teeth (spur-
type) of the first- and second-speed
synchronizer sleeve. Movement of
the sliding gear is accomplished by
the center shaft lever. With all for-
ward-speed synchronizer sleeves in
neutral, power flow in reverse is
through the input shaft to the con-
stant-mesh countershaft (cluster)
gear, thence to the constant mesh re-
verse idler. Splines then carry the
power through the reverse sliding
gear to the first-and-second speed
synchronizer sleeve which is locked
to the output shaft. As the reverse
sliding gear is meshed with the syn-
chronizer sleeve, power is transmit-
ted to the output shaft, rotating it in
FIG. 2-Power Flow a reverse direction.

SHIFT LINKAGE
ADJUSTMENT
1. Loosen the three shift linkage
adjustment nuts. Install a Y4 inch
diameter alignment tool through the
control bracket and levers as shown
in Fig. 3.
An alignment tool can be made
from 1/4" diameter drill rod bent to
an "L" shape. The extensions should
be lV2" and 33/4'; from the elbow.
Short end of alignment pin should
be inserted into control bracket and
linkage holes until it bottoms.
2. Tighten the three linkage ad-
justment nuts and then remove the
alignment pin.
3. Check the gear shift lever for
a smooth crossover.
 PART 6-5
FIG. 3-Adjusling Shift Linkage
REMOVAL AND INSTAllATION
REMOVAL
1. Raisethe car on a hoist.
2. Disconnect the drive shaft
from the rear U-joint flange. Slide
the drive shaft off the transmission
output shaft and install the exten-
sion housing seal installation tool
into the extensionhousingto prevent
lubricantleakage.
3. Disconnect the speedometer
cable from the extension housing.
4. Removethe retaining clip, flat
washer and spring washer that se-
cures the shift rods to the shift le-
vers.
5. Remove the bolts that attach
the shift linkage control bracket to
the extensionhousing and allow the
assemblyto hang by the shift lever.
6. Support the engine with a
transmissionjack and remove the
two nuts securing the transmission
rear support to the crossmember.
7. Raise the rear of the engine
with the transmissionjack. Remove
the two nuts, washersand bolts se-
FORD DESIGNFOUR-SPEED
TRANSMISSION
C1590-A
curing the crossmember to the frame
supports. Remove the crossmember.
8. Support the transmission on a
jack and remove the bolts that at-
tach the transmission to the flywheel
housing.
9. Move the transmission and
jack rearward until the transmission
input shaft clears the flywheel hous-
ing. If necessary, lower the engine
enough to obtain clearance for
transmission removal.
Do not depress the clutch pedal
while the transmission is removed.
INSTALLATION
1. Make sure that the mounting
surfacesof the transmissionand the
flywheel housing are free of dirt,
paint, and burrs. Install two guide
pins in the flywheel housing lower
mountingbolt holes.Move the trans-
mission forward on the guide pins
until the input shaft splinesenter the
clutch hub splinesand the caseis po-
sitionedagainstthe flywheelhousing.
6-37
2. Install the two upper transmis-
sion to flywheel housing mounting
bolts snug and then remove the two
guide pins. Install the two lower
mounting bolts. Torque all mounting
bolts to specifications.
3. Raise the rear of the engine
high enough to provide clearance for
installing the crossmember. Install
the two crossmember-to-frame sup-
port attaching bolts, washers, and
nuts. Do not tighten at this time.
4. Align the bolts in the transmis-
sion rear support with the bolt holes
in the crossmember, then lower the
engine and remove the jack. Install
the two transmission rear support-
to-crossmember washers and nuts
and torque to specifications. Tighten
the crossmember-to-frame support
nuts.
s. Position the shift linkage con-
trol bracket to the extension housing
and install the attaching bolts.
6. Secure each shift rod to its re-
spective lever with the spring wash-
 6-38 GROUP 6 MANUALSHIFTTRANSMISSIONS

er, flat washer, and retaining pin.
7. Connect the speedometer cable
to the extension housing.
8. Remove the extension housing
installation tool and slide the for-
ward end of the drive shaft over the
transmission output shaft. Connect
the drive shaft to the rear V-joint
flange.
9. Place both forward gear shift
levers and the reverse shift lever in
the neutral position and insert a 1/4
inch diameter alignment tool in the
shift linkage alignment hole (Fig. 3).
Adjust the linkage and tighten the
adjusting nuts. Remove the align-
ment tool. Adjust the clutch pedal
free travel as required.
10. Fill the transmission to the
proper level with the specified lubri-
cant.
11. Lower the car. Check the
shift crossovermotion for full shift
engagementand smooth crossover
operation.

~
I MAJOR REPAIR OPERATIONS
DISASSEMBLY
1. Mount the transmissionin a ;'-SET SCREW. 377885.S
holding fixture and drain the lubri-
cant. !l-SPRING .7234

2. Remove the cover attaching

screwsfrom the case.Lift the cover (4-DETENT PLUG.7C316
and gasketfrom the case. FIRST AND SECOND SPEED SHIFT RAIL
7240
3. Removethe extensionhousing
attaching screws and lock washers.
Removethe housingand the gasket.
THIRDAND FOURTH
. SPEEDSHIFTFORK. 7230 . ffi_SCREW.
\)!
377886. S

4. Removethe input shaft bearing , , FIRST

SPEEDAND SECOND
SHIFT FORK
-SCREW. 377886.S
retainer attaching screws.Slide the DETENT PLUG-@
retainer off the input shaft. 7C316
INTERLOCKPINR
S. Support the countershaft gear ) 7235 Y
with a wire hook. Working from the
front of the case,push the counter- SCREW ~
'7886 . 5 \3
shaft out the rear of the case as
shownin Fig. 4. Lower the counter- THIRDAND FOURTH
..~-
shaft to the bottom of the casewith SPEEDSHIFTRAIL
\~
the wire hook. Removethe hook. 7241 tJ]

~
~.-"~T--
REVERSE
SHIFTRAil REVERSE
SHIFTFORK
7?1'
i

~
~::::;;:;;~ ~
I
t~
~
Too/--T64P-7111-A
EXPANSION
'LUG-74112-S ,~i ~
~,
!1 j DETENTPLUG-7C316
FIG. 4-Removing Countershaft ---
from Case \-
QU7.D
6. Placethe first-and-second-speed SPRING .I
,
gear shift lever and the reverseshift
lever in the neutral position. Place
,1\,.
""\I'
7234

the third- and fourth-speedgear shift
lever in the third-speedposition.
7. Remove the bolt that retains
the third- and fourth-speedshift rail
detentspring and the plug in the left
side of the caseas shown in Fig. 5.
Removethe spring and the plug with
a magnet.
8. Removethe detent mechanism
set screw from the top of the case.
Remove the detent spring and plug
with a small magnet.
9. Remove the attaching; screw
~
BOLT
/
78206.5
(!fj-MAGNETIC
DRAIN PLUG -373719
C 1568- A
FIG. 5-Shift Rails and ForksDisassembled
from the third- and fourth-speed shift Do not lose the interlock pin from
fork. Tap on the inner end of the the shift rail.
shift rail to unseal the expansion plug 10. Remove the set screw from
from the front of the case. Then the first- and second-speedshift fork.
withdraw the third- and fourth-speed Slide the first- and second-speedshift
shift rail from the front of the case. rail out the reaT nf th~ ca~e
 PART 6-5 - FORDDESIGNFOUR-SPEED
TRANSMISSION
6-39

11. Removethe interlock plug and
the detent plug from the top of the
case(Fig. 5) with a magnet.
12. Removethe snapring that se-
cures the speedometerdrive gear to
the output shaft. Slide the gear off
the shaft, then removethe speedom-
eter gear drive ball.
13. Removethe snapring that se-
curesthe output shaft bearingto the
shaft.
14. Removethe output shaft bear-
ing as shownin Fig. 6.
21. Lift the reverseidler gear and
the thrust washersfrom the case.Be
careful not to drop the bearingsand
the dummy shaft from the gear.
22. Lift the countershaftgearand
the thrust washersfrom the case.Be
careful not to drop the bearingsor
the dummy shaft from the counter-
shaft gear.
23. Remove the snap ring from
the front of the output shaft. Slide
the third- and fourth-speedsynchro-
nizer (Fig. 11) blocking ring and the

FIG. 8-Removing Output

Shaft Assembly

Toof-T63P-7025-

Tool-T64P-7025-B
- DETAil 1

DETAil 4
FORD, FAIRlANE
. AND MERCURY
DETAIL 5
COMET AND FALCON
-" --~ ~

Tool-T52T-6500-DJD C1513.A

DETAIL2
FIG. 9-Rotating Reverse
Shift Rail

C1533-A
FIG. 6-Removing Output Shaft Bearing
15. Remove the input shaft and HIRD
bearing and the blocking ring from T
~vn'
the front of the case. SPEED
SHIFT
16. Move the output shaft to the .ORK
right side of the case to provide
clearancefor the shift forks. Rotate
the forks as shownin Fig. 7, then lift ""

them from the case. FIRST AND

17. Supportthe thrust washerand .REVERSE

first-speedgearto preventthem from
sliding off the shaft, then lift the out-
put shaft assemblyfrom the caseas
shownin Fig. 8.
18. Removethe reversegear shift
fork set screw. Rotate the reverse
shift rail 90° as shown in Fig. 9.
Slidethe shift rail out the rear of the
case.Lift the reverseshift fork from
the case.
19. Remove the reverse detent
plug and spring from the casewith
a magnet.
20. Remove the reverse idler gear
shaft from the case as shown in Fig.
10.
SPEED
SHIFT
FORK
FIG. 10-Removing Reverse
Idler Gear Shaft
.
25. Remove the next snap ring,
~v.. v. ~..~.. ..,~."~ --_c c-
TO RIGHTSIDEOF CASE C1527-A then slide the first- and second-speed
synchronizer,blocking ring and the
FIG. 7 -Removing Shift Forks first-speedgear off the shaft.
26. Remove the thrust washer
from Case
from the rear of the shaft.
third-speedgear off the shaft.
24. Removethe next snap ring PARTS REPAIR OR
and the second-speedgear thrust REPLACEMENT
washerfrom the shaft. Slide the sec-
ond-speedgear and the blocking ring GEAR SffiFf LEVER
off the shaft. 1. Remove the snap riD
6-40
FIG. 11-0utput Shaft Disassembled
end of the selectorshaft with pointed
snapring pliers (Fig. 12).
2. Remove the flat washer and
spring.
3. After removing two bolts, pull
the retainer, selector levers, and
bracket from the shaft.
4. Drive the short selector lever
pin from the shaft with a large pin
punch.
5. Drive the long trunnion pin
from the shaft and removethe trun-
nion and shaft.
6. If necessaryto removethe studs
from the selectorlevers,removethe
cotter pins, flat washers, wave
washersand studs.
7. Lubricate all mating friction
surfaceswith Lubriplate before as-
sembly.
8. Install the shaft in the bracket.
GROUP 6 - MANUALSHIFTTRANSMISSIONS
Position the trunnion and drive the
long straight pin through the trun-
nion and into the shaft until an equal
length of the pin is exposed on both
sides of the shaft.
9. Drive the short pin into the
shaft until the pin is centered in the
shaft.
10. Install the levers and the neu-
tral index bracket on the shaft as
shown in Fig. 12.
11. Position the retainer and start
the bolts. Before tightening the bolts
be sure that the retainer is not inter-
fering with free movement of the
shaft. Tighten the bolts.
U. Install the spring, flat washer
and snap ring.
13. Install the lever studs if they
were removed.
CAM AND SHAFT SEALS
1. Remove the attaching nut, lock
washer and the flat washer from
each shift lever and remove the three
levers.
2. Remove the three cam and
shafts from inside the case.
3. Remove the O-ring from each
cam and shaft (Fig. 13) and discard
the O-rings.
4. Dip the new O-rings in gear lu-
bricant and install them on the cam
and shafts.
5. Slide each cam and shaft into
its respective bore in the transmis-
sion case.
6. Position a shift lever on each
cam and shaft and secure with a flat
washer, lock washer and nut.
INPUT SHAFT BEARING
1. Remove the snap ring that se-
 PART 6-5 - FORD DESIGNFOUR-SPEED
TRANSMISSION 6-41

.. a .. SHAfT ROLLER BEARINGS

\
INPUT
,R~TAINERW
, , AND GEAR

~w
I:' '~~ If :'

-- - ASSEMBLY ,
i

SPRING Ii i
I PLUNGER ..I
-' I'" .-r
,
PIN (LONG) v..I '..- -- FRONT BEARING
SC:IECTORSHAFT R,nr.""""
~.~_.,..,~ DO"""
n..'~
RFvERSESELECTOR SNAP RINGS C1415-8
LEVER
FIG. 14-lnput Shaft Gear Disass4

,~ } NEUTRALINDEX mbled
I ~'"
~'f;,j' , 1-2BRACKET
SELECTOR
2. Pressthe input shaft gear out 3. Position the hub in the sleeve,
SPACER,
TRUNNION ~'- ,~If> SNAP RINC'
,. LEVER
of the bearingas shownin Fig. 15.
3. Press a new bearing onto the
making sure that the alignment
marks are properly indexed.
STRAIGHT
PIN r~ SPRINr input shaft with the tool shown in 4. Place the three inserts into
(SHORT) ,
place on the hub. Install the insert
"'

Fig. 15.
COmR PIN-, 'd;!Ii,~..",1 4. Secure the bearing with a snap springs making sure that the irregu-
FLATWASHER--~W~
WAVEWASHER/' ~U~ r;r~e v':r f ring.
SYNCHRONIZERS
lar surface (hump) is seated in one
of the inserts. Do not stagger the
3-4 SELECTORLEVER RETAINER / springs.
FLAT WASHER 1. Pushthe synchronizerhub from
C1406-8 each synchronizersleeve (Fig. 16). COUNTER..~n A.VI'~ I:WA.lI
~~~.~~ ~~._-
2. Separatethe inserts and insert R~ARINGS
FIG. 12-Gear Shift Lever springs from the hubs. Do not mix 1. Remove the dummy shaft, two
Disassembled-TvDical the parts of the first- and second- bearing retainer washers, and the 21
roller bearings (Fig. 17) from each
end of the coun\ershaft gear.
FIRST AND SECONDSPEED CAM AND SHAFT - 7C124 2. Coat the bore in each end of
REVERSE GEAR CAM
the countershaft gear with grease.
3. Hold the dummy shaft in the

~
AND SHAFT
7C124 gear and install the 21 roller bear-
~_o~ RING- 7288
ings and the retainer washer in each
end of the gear.

~ -
O.RING
REVERSEIDLER GEAR
BEARINGS
7288 ; 7005
,- 1. Slip the reverse idler sliding
FIRST AND SECO/"I"ISPEED SHIFT LEVER - 7290 gear off of the reverse idler gear
THIRDIAND FOURTH "~
(Fig. 18).
SPEED CAM AND SHAFT
7C124 1
"""
~ 5 2. Removethe dummy shaft, two
bearing retainer washersand the 44
roller bearingsfrom the reverseidler
( , gear.
3. Coat the bore in each end of
the reverseidler gear with grease.
r,J
4. Hold the dummy shaft in the
'-- REVERSE SHIFT LEVER - 7290 gear and install the 22 roller bear-
"-- I
--'
ings and the retainer washerin each
end of the gear.
~ ~ Q~
(co: 5. Install the reverseidler sliding
! gear on the reverseidler gear mak-
44727- .
'-- ing sure that the shift fork grooveis
34807-5.
33800-5 toward the front (Fig. 18).
, ~
INPUT SHAFf SEAL
THIRD AND FOURTH
SPEED SHIFT L.EVFR - 7285 ,
44727-5 1. Removethe sealfrom the input
34807- 5 shaft bearing retainer as shown in
3380'0-
S Fig. 19.
2. Coat the sealing surface with
C1591-A
lubricant.
3. Install the seal as shown in
FIG. 13-Cam and Shaftsand Shift Levers Disassembled Fig. 20.

cures the bearing to the shaft speed synchronizer with the third- ASSEMBLY
(Fig. 14). and fourth-speed synchronizer. 1. Coat the countershaft gears
 6-42 GROUP 6 - MANUALSHIFTTRANSMISSIONS

end play, install the dummy shaft in

the countershaft gear and allow the
gear to remain at the bottom of the
case.
6. Coat the reverse idler gear
thrust surfaces in the case with a thin
film of lubricant and position the two
thrust washers (Fig. 18) in place.
7. Position the reverse idler gear,
sliding gear, dummy shaft and the
roller bearings in place making sure
that the shift fork groove in the slid-
ing gear is toward the front of the
case.
8. Align the gear bore and thrust
washers with the case bores and in-
stall the reverse idler shaft.
9. Measure the reverse idler gear
-~ ~~~'.l""""=- --- end play with a feeler gauge. End
REMOVAL INST ALLA nON C1403-B play should be 0.004-0.018 inch. If
the end play is not within limits, re-
FIG. 1 5-Replacing Input Shaft Bearing
place the thrust washers. If the end
play is within limits, leave the reverse
idler gear installed.
10. Position the reverse gear shift
rail detent spring and detent plug in
the case. Hold the reverse shift fork
in place on the reverse idler sliding
gear and install the shift rail from
the rear of the case. Secure the fork
to the rail with the Allen head set
screw.
11. Install the first- and second
speed synchronizer onto the front of
the output shaft (Fig. 11) making
sure that the shift fork groove is to-
ward the rear of the shaft.
12. Position the blocking ring on
the second-speedgear.
ETCHMARKS 13. Slide the second-speed gear
SLEEVE onto the front of the shaft, make sure
INSERT~ INSERT SPRING that the inserts in the synchronizer
engage the notches in the blocker
,INSERT SPRING
INSERT ring.
14. Install the second-speed gear
thrust washer and snap ring.
INSERT ( 15. Slide the third-speed gear onto
(
the shaft with the synchronizer coned
surface toward the front.
16. Place a blocking ring on the
third-speed gear.
GROOVE TO FACE 17. Slide the third- and fourth-
TOWARD FRONT
speed gear synchronizer onto the
- OF TRANSMISSION
shaft making sure that the inserts in
THIRD AND FOURTH SPEED SYNCHRONIZER C1523-A
the synchronizer engage the notches
FIG. 16-Synchronizers Disassembled in the blocking ring.
18. Install the snap ring on the
thrust surfacesin the casewith a thin thrust washerswith the bores in the front of the output shaft.
film of lubricant and positiona thrust caseand install the countershaft. 19. Position the blocking ring on
washer(Fig. 17) at each end of the 4. Place the casein a horizontal the first-speed gear.
case. position and check the countershaft 20. Slide the first-speed gear onto
2. Position the countershaftgear, gear end play with a feeler gauge. the rear of the output shaft making
dummy shaft, and roller bearingsin The end play should be 0.004-0.018 sure that the notches in the blocking
the case. inch. If not within these limits, re- ring engage the synchronizer inserts.
3. Place the casein a vertical po- place the thrust washers. 21. Install the heavy thrust washer
sition. Align the gear bore and the 5. After establishing the correct on the rear of the output shaft.
~
 PART 6-5 FORD DESIGN FOUR-SPEED
TRANSMISSION 6-43

27. Align the first- and second-

speed shift fork with the case bores
and slide the shift rail into place. Se-
cure the fork with the set screw. In-
stall a detent plug and spring in the
detent bore. Thread the set screw into
the case until the head is flush to
0.020 inch below the surface of the
case.
28. Coat the input gear bore with
a thin film of grease, then install the
15 roller bearings in the bore. A
THRUST thick film of grease could plug the
WASHER lubricant holes and restrict lubrica-
7119
tion to the bearings.
;/
29. Position the front blocking
j " .,i' ring in the third- and fourth-speed
synchronizer. Place the input shaft
gear in the transmission case making
;-ROLLER BEARINGS- 7 sure that the output shaft pilot enters
C 1512- B
the roller bearings in the input gear.
30. Place a new gasket on the in-
put shaft bearing retainer. Dip the
FIG. 17 -Countershaft Gear Disassembled attaching bolts in sealer and install
and tighten them to specifications.
REVERSE IDLER 31. Install the output shaft bear-
GEAR SHAFT
7"0 ing as shown in Fig. 21. Install the
snap ring to retain the bearing.
32. Position the speedometer gear
ROLLERBEARINGS ~~,n'
7D271(22) ".,. drive ball in the output shaft and
slide the gear into place. Secure the
""""""""~~""""'~ . gear with the snap ring.
~~ C) '\J "THRUST WASHER 33. Place the transmission in a
7149 vertical position as shown in Fig. 22.
, Align the countershaft gear bore and
thrust washers with the bore in the
RETAINER
WASHER
351529.5 ~ /.,>'
I
j ~ case. Install the countershaft.
34. Use a new gasket and secure
"\.~\
""' ("\, ~ --- .REVERSE IDLER GEAR. 7142 the extension housing to the case

~"'~
"""'""
\\
I~
\ '
\
- . REVERSE
- -
c~",~#
"!iii/~~
SLIDING
.--':THRUST
WASHER. 7149
FIG. 1 8-Reverse Idler Gear Disassembled
21.. Support the thrust washer and
first-speed gear to prevent them
from sliding off the shaft. Carefully
lower the output shaft assembly into
the case as shown in Fig. 8.
23. Position the first- and second-
speed shift fork and the third- and
fourth-speed shift fork in place on
their respective gears and rotate
them into place.
24. Place a detent plug (Fig. 5) in
the detent bore. Place the reverse
shift rail into neutral position.
25. Coat the third- and fourth
speed shift rail interlock pin with
grease and position it in the shift rail.
~~
~
GEAR. 7D223
C 1528- B
26. Align the third- and fourth-
speed shift fork with the shift rail
bores and slide the shift rail into
place making sure that the three de-
tents are facing toward the outside
of the case. Place the front synchro-
nizer into third-speed position and in-
stall the set-screw in the third- and
fourth-speed shift fork. Move the
synchronizer to the neutral position.
Install the third- and fourth-speed
shift rail detent plug, spring and bolt
in the left side of the transmission
case (Fig. 5). Place the interlock
plug (tapered ends) in the detent
bore.
with the attaching screws. Use a seal-
er on the extension housing attach-
ing screws. Torque the screws to
specifications.
35. Install the filler and drain
plugs in the case if they were re-
moved. Make sure that the magnetic
plug is installed in the bottom of the
case.
36. Pour the specified lubricant
over the entire gear train while rotat-
ing the input shaft.
37. Place each shift fork in all po-
sitions to make sure that they oper-
ate properly.
38. Use a new cover gasket and
install the cover. Coat the cover at-
taching screws with sealer and install
and tighten them to specifications.
39. Coat the third- and fourth-
speed shift rail plug bore with a seal-
er and install a new expansion plug.
40. If the extension housing bush-
ing and seal are to be replaced, re-
fer to Section 4.
 6-44 GROUP 6 - MANUALSHIFTTRANSMISSIONS

FIG. 22-lnstalling
-- -.
C1526-A
Countershaft
FIG. 19-Removing Input Shaft Seal

Tool-T63P-7025-A.

-Toof-T64P,7025.B
DETAIL 1

DETAIL 4
FORD, FAIRLANE
- DETAilS
AND MERCURY

COMET AND FALCON

,DETAil 3

'DETAil 2

C1518-A
FIG. 21-lnstalling Output Shaft Bearing
 6-45

OVERDRIVE TRANSMISSION

Section Page Section Page

1 Diagnosis and Testing. . . . . . . . . . . . . .6-45 MechanicalOperation. . . . . . . . . . . . .6-47
Overdrive Control Handle Clearance
Mechanical Checks .6-45 Electrical System Operation. . . . . . . .6-48
4 In-Car Adjustments and Repairs. . . . . .6-49
Check. . . . . . . . . . . . . . . . . . . . . . 6-45 Overdrive Control Cable Adjustment. .6-49
Overdrive Control Lever Position 5 Transmission Removal and Installation .6-50

Check. . . . . . . . . . . . . . . . . . . . . .6-45 Removal. . . . . . . . . . . . . . . . . . . . . . . . . .6-50

Electrical Governor
Pawl Engagement Checks Circuit Check. Check ........ 6-45 Installation. . . . . . . . . . . . . . . . . . . . . . . .6-50
.6-45 6 Major Repair Operations. . . . . . . . . . . .6-50
.6-45 Parts Repair or Replacement. . . . . . . . .6-50

Disassembly
Interrupter Circuit Check.
Solenoid Circuit Check ...... .6-46 .6-52
.6-46 Synchronizer.
InputShaft ............ ...... .6-52

Cleaning. ...................... .6-47 .6-52

2
Cleaning
and
Inspection
.6-47 Output Shaft Bearing. . . . . . . . . . . . .6-52
Inspection. . . . . . . . . . . . . . . . . . . . . . . .6-47 Cam and Shaft Seals , .6-52
Description. . . . . . . . . . . . . . . . . . . . . 6-47 Countershaft Rollers. . . . . . . . . . . . . .6-53
3
Description
and
Operation
.6-47 Assembly. . . . . . . . . . . . . . . . . . . . . . . . .6-53
Operation. . . . . . . . . . . . . . . . . . . . . . . .6-47

DIAGNOSIS AND TESTING

When trouble occurs in the over- in third or second gear, shift the does not engage, remove the over-
drive unit, check the mechanical op- overdrive control lever to the locked- drive unit from the car for inspec-
eration of the unit before checking out (forward) position. The drive tion and repair.
the operation of the overdrive elec- shaft should lock up when turned
trical control system. either clockwise or counterclockwise. ELECTRICALCHECKS
GOVERNOR CIRCUn CHECK
MECHANICAL CHECKS PAWL ENGAGEMENT CHECK
1. Turn the ignition switch ON
Check the mechanical engagement
OVERDRIVE CONTROL and OFF, and listen for the relay or
HANDLE CLEARANCE CHECK of the pawl with the balk ring gear,
solenoid to click. If either clicks as
using the following procedure:
Check the specified clearance be- soon as the ignition switch is turned
1. Turn the ignition switch to the ON, the governor circuit (Fig. 1) is
tween the overdrive control handle ON position and raise the car.
shank and the bezel on the instru- grounded or the relay is defective.
2. Shift the overdrive control lever 2. To determine which condition
ment panel.
to the locked-out (forward) position, is present, remove the wire from the
OVERDRIVE CONTROL LEVER and shift the transmission to neutral. TH-SW terminal on the relay and
POSITION CHECK 3. Turn the drive shaft clockwise turn the ignition switch ON. If the
Raise the car and check the posi- and, at the same time ground the relay clicks, the relay is defective. If
tion of the overdrive control lever at governor white wire with a jumper. it does not click, the governor circuit
the overdrive unit housing. The lever The solenoid will click, indicating is grounded.
should rest firmly against its stop at that it is energized. 3. To check the governor opera-
the rear. If the lever is not all the 4. Keep the solenoid energized, tion when the relay does not click as
way back the overdrive shift rail and shift the transmission to third or the ignition switch is turned On, dis-
may be locking the pawl and pre- second gear to lock the transmission connect the wire at the TH-SW ter-
venting it from engaging the balk output shaft against rotation. Shift minal.
ring gear. the overdrive control lever to the au- 4. Raise the rear wheels off the
With the engine stopped and the tomatic (rearward) position. floor.
clutch engaged, shift the transmission 5. Turn the drive shaft clock- 5. Connect a test lamp between
to third or second gear and shift the wise. At less than 1/4 turn of the the battery and the wire removed
overdrive control lever to the auto- driveshaft, the pawl will engage the from the TH -SW terminal.
matic (rearward) position. The drive balk ring gear and lock the drive 6. Start the engine and, with the
shaft should then turn freely in a shaft against rotation in both direc- transmission in third-speed, bring the
clockwise direction (when viewed tions. speedometer reading up through 28
from the front), but should lock up If the pawl does not engage the mph. The lamp should light at or
when turned counterclockwise. balk ring gear, replace the solenoid about this speed.
With the transmission remaining and repeat the test. If the pawl still 7. Throttle the en gin e down
6-46 GROUP6
FIG. 1-0verdrive Electrical System
through 22 mph and at or about this
speedthe lamp should go out. If the
lamp lights, and goesout at or about
thesespeeds,the governor and gov-
ernor circuit are working properly.
8. Turn the ignition switch ON
and raisethe car. Disconnectthe yel-
low wire from the white wire at the
governorconnector.
9. Ground the white wire on the
transmissioncase. If the relay and
solenoidclick, the governorcircuit is
working properly from the TH-SW
terminal to the connector (Fig. 1),
and the trouble is in the yellow wire
or the governor.If the relay and so-
lenoid do not click when the white
wire is grounded,the trouble is be-
tween the TH -SW terminal and the
connector(Fig. 1).
SOLENOID CIRCUIT CHECK
1. With the engine stopped and
the ignition switch ON, ground the
TH -SW terminal on the relay. If
the relay and solenoid click as the
ground is madeand broken, the sole-
noid circuit is working properly. If
the relay doesnot click as the TH-
SW terminal is grounded,check the
relay IGN terminal with a test lamp.
2. With the ignition switch ON,
the test lamp should light when it is
connectedbetweenthe IGN terminal
on the relay and at a ground. If it
does not, the trouble is betweenthe
ignition switch and the IGN termi-
nal.
3. Connect the test lamp at the
other end of the fuse and at a
MANUALSHIFTTRANSMISSIONS
ground. If the lamp lit at the IGN connected to the BAT terminal dur-
end and not at the other, replace ing ignition work. .
the fuse. Sometimes the fuse will Z. Disconnect the blue wire with
"open" under the fuse end caps where an orange band (Fig. 1) from its
the "open" cannot be seen. connector near the solenoid, and
4. With current at both ends of the ground it to the transmission case
fuse, connect the test lamp between with a jumper.
the solenoid terminal and at a 3. With the engine running at fast
ground. Ground the TH-SW termi- idle, push the kickdown switch stem
nal. The lamp should light. If it does in until it bottoms (Fig. 2). When
not, replace the relay. the stem bottoms, the engine should
5. With the relay working proper- stop.
ly, the solenoid should click when the
TH-SW terminal is grounded. If it
does not, connect a jumper from the
SOLENOID relay terminal to the
short blue wire separated from its
connector near the solenoid. If the
solenoid does not click when the re-
lay closes with the jumper wire con-
nected, replace the solenoid. If it
does click, replace the wire from the
SOLENOID relay terminal to the
connector.
INTERRUPTER CIRCUIT
CHECK
If the interrupter circuit does not
ground the engine ignition momen- STEM BEUCRANK ..~;-; s;-~
tarily when the driver depressesthe
accelerator pedal to the floor, the FIG. 2-Kickdown Switch
overdrive unit cannot shift from over- Installation
drive to direct.
1. The first check of the ignition If it does not stop, the circuit is
interrupter circuit is at the ignition open between the ruST terminal
coil. The black wire which runs and the connector.
from the ignition coil to the kick- 4. To check the ignition ground-
down switch must be connected to ing contactsinside the solenoid,dis-
the DIST terminal on the coil. connect the jumper and removethe
Sometimes this wire is improperly solenoidfrom the overdrive unit.
 PART 6-6-
S. Attach the solenoid to an
adapterso that the stem can extend
fully when the solenoidis energized.
Make sure the solenoidis grounded.
CLEANING
Clean and inspect the transmis-
sion unit parts in the samemanner
as for the conventional transmis-
sion. Clean all overdrive parts thor-
oughly.
INSPECTION
Check the balk ring tension, as
shown in Fig. 3 for a pull of 31/2-51/2
pounds. Read the spring scale while
the balk ring is turning, because the
initial effort required to start the
ring turning may be considerably
higher than the specified pull. Re-
place the assembly if the tension is
not within specifications.
Check the inner surface of the
free-wheel clutch outer race. If the
surface is worn or "chattered," the
overdrive output shaft must be re-
placed.
DESCRIPTION
The overdrive transmission is used
on Fairlane cars having 289 C.I.D.
engines. A transmission service iden-
tification tag is located under the up-
per right extension to case attaching
bolt. The tag will show the transmis-
sion model and service identification
code when required.
The overdrive unit is basically an
automatic planetary transmission at-
tached to the rear of a conventional
three-speed transmission (Fig. 4) to
provide four forward speeds instead
of three. The overdrive can be me-
chanically locked out by a control ca-
ble located on the instrument panel.
The electrical system which con-
trols the operation of the overdrive
when the control cable is pushed in,
consists of a relay, a manual kick-
down switch, solenoid, governor, and
the circuit wiring.
OPERATION
MECHANICAL OPERATION
Direct, Free-Wheeling Drive
When the control handle is pushed
OVERDRIVETRANSMISSION
6. Connectboth solenoidwires at
their connectors.
7. Ground the governor wire with
a jumper.
8. With the enginerunning at fast
FIG. 3-Checking Balk Ring Tension
Checkthe clutch rollers for cracks
and wear. Replacethe completeset
in, the drive through the overdrive
unit from start to approximately 28
mph is direct (1.00:1) and free-
wheeling.
The power flow is from the trans-
mission output shaft, through the
overrunning clutch (free-wheel unit),
to the overdrive main shaft (Fig. 5).
This drive is said to be free-wheel-
ing because the overrunning clutch
permits the transmission output shaft
to drive the overdrive main shaft,
but it does not permit the drive to
reverse. In a free-wheeling drive, the
engine can drive the rear wheels, but
the rear wheels cannot drive the en-
gine.
In direct, free-wheeling drive, the
planetary gearing is in neutral, be-
cause the sun gear can run free. It
can rotate clockwise (from the
front), counterclockwise, or stand
still, depending on the relative
speeds of the planet carrier (trans-
mission output shaft), and the inter-
nal ring gear (overdrive main shaft).
At a 0.70: 1 ratio, the sun gear will
stand still. At a higher ratio, the sun
gear will turn clockwise (from the
6-47
idle, press in on the kickdown switch
stem until it bottoms. The engine
should stop. If it does not, replace
the solenoid.
of 12 rollers if any are cracked or
worn.
front). At a lower ratio than 0.70:1,
it will turn counterclockwise.
Overdrive
To shift the overdrive unit from
the direct (1.00:1) to overdrive
(0.70:1) the sun gear is held against
rotation (Fig. 5).
This is accomplished by engaging
a pawl in the balk ring gear which
is splined to the sun gear.
In overdrive, the power flow is
from the transmission output shaft
to the planet carrier splined to it,
through the planet gears and then
to the sun gear. With the sun gear
held against rotation, the planet
gears are forced to "walk around"
the sun gear and drive the internal
ring gear. The transmission output
shaft will then drive the overdrive
main shaft at a ratio of 0.70:1.
In overdrive, the overrunning
clutch is uncoupled becausethe outer
race (overdrive main shaft) is turn-
ing faster than the clutch cam (trans-
mission output shaft). Overdrive is a
two-way drive; the engine can drive
the rear wheels and the rear wheels
6-48 GROUP 6 - MANUALSHIFTTRANSMISSIONS
4-0verdrive Transmission
TRANSMISSION OVERDRIVE
OUTPUT SHAFT MAIN SHA"T
--
OVERRUNNING
CLUTCH
SOLENOID
. 5-0verdrive PowerFlow
can drive the engine.
To shift from overdrive back to di-
rect, the pawl is disengaged from the
balk ring gear, permitting the sun
gear to run free. The overdrive gear-
ing is now in neutral. As soon as the
speed of the transmission output
shaft comes up to the speed of the
overdrive main shaft, the overrunning
clutch automatically locks up and di-
rect drive is restored.
Locked-Out Drive
When the control handle is pulled
out, the overdrive unit cannot func-
tion at any car speed. This lockout is
accomplished by the shift rail moving
the sun gear into engagement with
BALK RING B~LK RING INTERNAl
GFAI?
,,PLANET
PAWL CARRIER
. GEAR
-,
SUN
GFAR
'.3'8
OVERDRIVE
the lock-up teeth on the planet car-
rier (Fig. 5).
When the sun gear is locked to the
planet carrier, the planetary gearing
is locked as one mechanical unit and
the transmission output shaft is
locked to the overdrive main shaft.
This lock-up is necessary in reverse,
becausethe transmission output shaft
reverses its rotation and therefore
cannot drive the overdrive main
shaft through the overrunning (one-
way) clutch. The lock-up in reverse
is accomplished by the low and re-
verse position. This locked-up drive
is also necessary when the car is
pushed to start the engine, since the
overrunning clutch will not transmit
LOCK-UP TEETH
-
SHIFT
RAil
SUN GEAR
C1107-4
power from the overdrive main shaft
to the transmission output shaft.
ELECTRICAL SYSTEM
The overdrive electrical system,
which engages and disengages the
pawl, consists of a relay, a manual
kick-down switch, a solenoid, a cen-
trifugal governor and the circuit
wiring.
There are three separate circuits
(Section 1, Fig. 1) in the electrical
system: a governor circuit which
opens and closes the relay, a sole-
noid circuit which supplies current
through the relay to energize the so-
lenoid, and an ignition interrupter
circuit, which momentarily grounds
 PART 6-6 -
the engine ignition for full-throttle
downshift (kickdown).
Pawl Engagement
The electrical system does not op-
erate until car speed reaches approx-
imately 28 mph. At this speed, the
governor contacts close, permitting
current to flow from the battery
through the relay to the solenoid.
There are two coils in the sole-
noid, usually referred to as the "pull-
in" and "hold-in" coils. The pull-in
coil is energized only while the sole-
noid plunger is being pulled in. As
soon as the plunger is in, a set of
points inside the solenoid opens the
pull-in circuit.
As the plunger is pulled in, an en-
gaging spring and a return spring are
engaged.
Under pressure from the pawl en-
gaging spring, the pawl is pushed in
until it strikes the balk ring.
The usual position of the balk
ring when the solenoid engaging
spring pushes the pawl against it is
shown in the left view of Fig. 6.
When the transmission output shaft
BALK RING GEAR SUN GEAR
SOLENOID BALK RING POSITION
STEM (ENGINE DRIVING)
FIG. 6-Pawl and Balk Ring Positions
IN-CAR ADJUSTMENTS AND REPAIRS
OVERDRIVE CONTROL
CABLE ADJUSTMENT
1. Loosen the overdrive cable
lock nut at the overdrive control le-
ver.
~
OVERDRIVETRANSMISSION
is driving the overdrive main shaft
through the overrunning clutch, all
elements of the planetary gearing
are revolving as a unit, and in a
counterclockwise (from the rear) di-
rection. This rotates the balk ring
against the pawl.
When the driver releases the
throttle, the overdrive main shaft
overruns the transmission output
shaft. When this overrun exceeds the
ratio of 0.70: 1, the sun gear and
balk ring reverse, releasing the pawl
to engage the balk ring gear.
The position of the balk ring,
should the solenoid be energized
when the car is coasting (engine
idling) up through 28 mph, is shown
in the right view of Fig. 6. Under
this condition the sun gear will be
rotating clockwise (from the rear)
and the pawl will be blocked.
The pawl engageswhen the engine
speeds up, and brings the transmis-
sion output shaft up through the
0.70:1 ratio with the overdrive main
shaft. This action will cause the sun
gear to reverse its clockwise (from
the rear) rotation and release the
pawl to engage the bulk ring gear.
/~{
.
,// ~
BALK RING POSITION
(COASTING)
2. Positionthe overdrivecableun-
til there is 1/4inch clearancebetween
the cablecontrol handleand bezel.
3. Move the overdrive control le-
ver to the rear againstthe stop.When
6-49
Pawl Disengagement
The pawl disengages under two
conditions. First, when the car speed
drops below approximately 22 mph,
the governor opens the circuit
through the relay and de-energizes
the solenoid, permitting the return
spring to pullout the pawl. Second,
the driver may shift the overdrive
back to direct drive at any road
speed, by pressing the accelerator
pedal to the floor so that it depresses
the kickdown switch stem.
When this happens, the kickdown
switch opens the governor circuit
through the relay, and de-energizes
the solenoid, permitting the return
spring to try to pullout the pawl.
Also, it closes the interrupter cir-
cuit and grounds the ignition long
enough for the return spring to pull
out the pawl.
Normal ignition is restored as
soon as the pawl comes out, and the
solenoid stem opens the ignition
grounding contacts. The actual time
of ignition interruption is equal to
that required for one revolution of
the crankshaft.
PAWL ENGAGED C 1574- A
moving the lever, be careful not to
move the cable out of position.
4. Tighten the control cable lock
nut on the overdrive.
6-50 GROUP 6 - MANUALSHIFTTRANSMISSIONS
REMOVAL
The overdrive unit cannot be re-
moved from the car as a separate
assembly. Remove the transmission
and overdrive unit together, follow-
ing the steps detailed below:
1. Disconnect the solenoid and
governor wires from the connectors
near the solenoid.
2. Remove the overdrive wiring
harness from its clip on the trans-
mission.
3. Disconnect the overdrive con-
trol cable from the lever on the side
of the overdrive unit and from the
clamp at the solenoid.
DISASSEMBLY
1. Mount the transmissionin a
holding fixture. Then, drain the trans-
missionand the overdriveunit.
2. Remove the solenoid retaining
screw, and then rotate the solenoid
about 1/4turn to removeit.
3. Removethe governor.
4. Removethe transmissioncover
and gasket.
5. With a sharppunch, pierce the
snapring hole cover in the overdrive
housing (Fig. 7), and remove the
cover.
OVERDRIVE HOUSING
SNAP RING HOLE
/' C 1575~
fiG. 7-Removing Overdrive
Housing
6. Remove the four overdrive
housing to transmissioncase bolts,
and the overdrive control shaft pin.
7. Pull the overdrivecontrol lever
and shaft out as far as possible.
Spreadthe snapring that retainsthe
overdrive output shaft bearing and
then remove the overdrive housing
(Fig. 7).
It may be necessaryto tap the
overdrive output shaft with a soft-
faced hammer to free the output
shaft bearingfrom the housing.
8. Remove the overdrive output
shaft from the assembly.Catch any
4. Removethe overdrivetransmis-
sion from the car, following the pro-
ceduregiven in Part 6-2 for remov-
ing the 3-speedConventionalDrive
transmission.
Do not depressthe clutch pedal
while the transmissionis removed.
INSTALLATION
The overdrive unit must be assem-
bled and installed on the transmission
before the transmission is installed in
the car.
1. Install the overdrive transmis-
sion in the car, following the proce-
dure given in Part 6-2 for installing
of the free-wheel unit rollers that
drop out. Remove the rest of the
rollers.
9. Remove the speedometergear
retaining snap ring. Remove the
gear and drive ball.
10. If the overdrive output shaft
bearingis to be replacedusethe tools
shown in Fig. 8.
100/-1531-
Toof-
4621.K
j 15. With a drift, drive the coun-
REMOVAL INSTALLATION
C 1113-B
FIG. 8-Replacing Output
Shaft Bearing
11. Remove the free-wheel unit
retainers (Fig. 9). Then remove the
clutch, planet carrier, sun gear, and
shift rail.
12. Remove the snap ring from
the adapter, and then remove the
plate and trough, balk ring gear and
pawl.
13. Remove the input shaft bear-
ing retainer and gasket (Fig. 10).
Replace the input shaft seal with
the same tools that are used on the
conventional 3-speed transmission.
14. Rotate the overdrive adapter
the 3-speedConventional Drive trans-
mission.
2. Connect the overdrive control
cable to the lever on the side of the
overdrive unit. With the cable con-
nected, there must be 1/4 inch clear-
ance between the control handle
shank and the bezel when the lever
at the overdrive housing is against
its rear stops.
3. Connect the solenoid and gov-
ernor to the connectors near the so-
lenoid.
4. Install the overdrive wiring
harness in its clip on the transmis-
sion.
ClUTCH-TO-CARRIER RETAINER
~ '
CLUTCH-
TO-TRANSMISSIONOUTPUT
SHAFT RETAINER C1011-A
FIG. 9-Removing Free Wheel
Unit Retainer
to expose the countershaft lock, and
remove the lock.
tershaft toward the rear until it just
clears the hole at the front of the
case, support the countershaft gear
with a hook then push the counter-
shaft out of the rear with the tool
shown in Fig. 11.
16. Lower the countershaft gear
to the bottom of the case to provide
clearance for removal of the input
shaft and bearing. Tap the input
shaft and bearing out of the front of
the case.
17. Remove the shift lever shaft
retaining pins (Fig. 12).
18. Pull the low and reverse shift
lever out as far as it will go; then
remove the low and reverse fork.
19. Remove the overdrive adapter
and transmission output shaft as an
assembly (Fig. 13).
20. Remove the snap ring at the
front of the transmission output
 PART 6-6 OVERDRIVETRANSMISSION 6-51

FIG. 10-0verdrive TransmissionDisassembled

shaft, and then slide the synchronizer 21. Lift the countershaft gear, 11. Drive the reverse idler gear
intermediate gear, and the sliding thrust washers and dummy shaft shaft out of the rear of the casewith
low a~d reverse gear off the shaft. from the case. a brassdrift and a hammer,and re-
6-52 GROUP 6 - MANUALSHIFTTRANSMISSIONS
. --
Tool-T56P-7111-B C1012-A
FIG. 11-Removing
Countershaft
FIG. 12-Removing Shift
Lever Shaft Retaining Pin
FIG. 13-Removing Output
Shaft and Adapter
move the idler gear from the case.
1.3. Remove the lock plunger,
spring, pin, and detent balls from the
case (Fig. 14).
PARTS REPAIROR
REPLACEMENT
INPUT SHAFT BEARING
1. If the input shaft bearing is to
be replaced, remove the snap ring
that retains the bearing, and press
the bearing and baffle off the shaft
(Fig. 15).
2. Press a new bearing into place
on the gear and shaft.
SYNCHRONIZER
1. Disassemblethe synchronizer
LOW AND REVERSECAM DETENT BALLS INTERMEDIATE AND HIGH CAM C1119-8
FIG. 14-Cams and DetentBalls Installed
-
REMOVAL INSTALLATION
C1114-8
FIG. 1 S-Replacing Input
Shaft Bearing FIG. 16-Synchronizer
unit (Fig. 10) by sliding the inter- 3. Position the bafflein the adapt-
mediateand high sleeveoff the hub. er (Fig. 17). Tap the bearing and
Remove the three inserts and two shaft into place in the adapter.
springsfrom the hub. 4. Install the snap ring to retain
2. Assemblethe synchronizerunit the bearing.
by installing the two springs on the
hub and placing the three inserts in CAM AND SHAFf SEA~
the hub. Hook one spring end in an 1. Remove the nuts and lock
insert as shown in Fig. 16.
3. After lining up the etched SNAP RING BEARING
marks on the sleeveand hub splines,
slide the sleeveinto placeon the hub.
OUTPUT SHAFT BEARING
1. Remove the snap ring which
retains the output shaft in the adapt-
er (Fig. 17), and tap the bearing out
of the adapter. Remove the baffle
from the adapter.
2. Remove the snap ring and press
the old bearing off and the new bear-
ing _on with the tools shown in Fig.
-~--- --
TRANSMISSIONOUTPUT SHAFT (1117.8
18.
Install the snap ring to retain the FIG. 17-Removing Output
bearing. Shaft BearingSnapRing
 PART 6-6 - OVERDRIVE
REMOVAL INSTALLATION
C 1118.8
FIG. l8-Replacing Output
Shaft Bearing
washersthat securethe leverson the
cam and shaft units, and removethe
leversfrom the shafts and cams.
2. Remove the cams and shafts,
detent balls, pin, spring, and sleeve
(Fig. 10) from the case.
3. Remove the seals with a suit-
able puller and discard.
4. Install the new sealswith a suit-
abledriver.
5. Install the intermediate and
high cam and shaft assemblyin the
case.
6. Insert a detent ball, sleeve,
springand pin in the bore of the case.
Move the cam and shaft so that the
detent ball seatsin the neutral (cen-
ter) notch.
7. Install the low and reversecam
and shaft assembly,and then install
the leverson the shaftswith nuts and
lock washers.
8. Install a detent ball in the
sleeveat the low and reverse end.
Then push the low and reversecam
toward the detent ball far enoughto
hold the ball in place in the neutral
notch. The ball must seat in the
notch of the cam.
9. Install the shift lever shaft re-
taining pins (Fig. 12).
10. In order to assure positive
shifting, and eliminatethe possibility
of engagingmore than one set of
gearsat the sametime, the clearance
betweenthe ramp of one cam and
the sleevemust be checked.
COUNTERSHAFf ROLLERS
1. Remove the thrust washers
from eachend of the countershaft.
2. Removethe dummy shaft, re-
tainer washers,rollers, and spacer
from the countershaft gear.
3. Position the spacer and the
dummy shaft in the countershaft.
TRANSMISSION
4. Placea retainer washerin each
end of the countershaftgear.
5. Apply greaseto all of the roll-
ers and place them in each end of
the countershaftgear.
6. Apply grease to the two re-
maining retainer washersand to the
contact surface of the thrust wash-
ers. Install the retainer washersand
the thrust washerson eachend of the
gear.
ASSEMBLY
Always use new gasketsand gas-
ket sealer during assembly.To pro-
vide initial lubrication, apply a thin
coating of lubricant on all parts be-
fore installation.
1. Position the countershaftgear,
dummy shaft, and roller bearingsin
the case.
2. Place the case in a vertical
position.Align the gear bore and the
thrust washerswith the bores in the
caseand install the countershaft.
3. Place the case in a horizontal
position and check the countershaft
gear end play with a feeler gauge.
The end play should be 0.004-0.018
inch. If not within these limits, re-
place the thrust washers.
4. After establishingthe correct
end play, install the dummy shaft in
the countershaftgear and allow the
gear to remain at the bottom of the
case.
5. Install the reverseidler gear in
the case, with the chamfered gear
teeth endstoward the front.
6. Drive the reverse idler shaft
into the case,with the locking notch
aligned with the countershafthole.
7. Install the low and reverseslid-
ing gear on the output shaft, with
the shifter fork groove toward the
front.
8. Install the intermediategearon
the output shaft, with the clutch
teeth toward the front.
9. Placea b10cki~gring on the in-
termediategear, and install the syn-
chronizer assemblyon the transmis-
sion output shaft, with the hub
thrust surface toward the rear (Fig.
16). Install the snapring that retains
the synchronizer.
10. Install the shift forks in the
camsinsidethe transmissioncase.
The offset in the low and reverse
fork goes toward the front.
11. Install a new solenoidseal in
the overdrive adapter.
12. Place a new gasket on the
overdrive adapter and hold it in
place with gasket sealer.
13. Install the overdrive adaDter
6-53
and transmission outMtshaft assem-
bly in the transmission.
14. Engage the shift forks with
the high and intermediate sleeve, and
with the low and reverse sliding
gear.
15. Seat the overdrive adapter
squarely against the transmission
case, and secure with a cap screw.
16. Coat the bore of the input
shaft with a thin film of grease and
install the pilot roller bearings.
17. Place the blocking ring on the
input shaft gear and hold them in po-
sition. Move the input shaft forward
to seat the output shaft pilot in the
roller bearings of the input shaft.
18. Tap the input shaft and bear-
ing into the case with a soft ham-
mer, and at the same time line up
the slots in the blocking ring with the
synchronizer inserts.
19. Place a new gasket on the in-
put shaft bearing retainer, and hold
it in place with gasket sealer.
20. Install the input shaft bearing
retainer to the transmission case.
21. Swing the transmission to an
inverted position in the fixture.
22. Remove the cap screw hold-
ing the adapter in place. Pull the
adapter outward approximately 1/4
inch, and rotate it to expose the
countershaft hole.
23. Work the countershaft gear
in., normal position by rotating the
input and output shafts.
24. Push the countershaft into the
case from the rear.
25. Align the slots in the counter-
shaft with the slot in the reverse idler
shaft and install the lock plate.
26. Rotate the adapter to its nor-
mal position and set it squarely
against the transmission case. Check
the blocking rings to make sure the
slots are aligned with the synchroniz-
er inserts.
27. Swing the transmission so that
the input shaft is pointing down.
28. Place the balk ring gear as-
sembly and pawl in the adapter (Fig.
19).
29. Place the plate and trough as-
sembly in the adapter and install its
snap ring.
30. Install the sun gear and shift
rail (Fig. 20).
31. Install the planet carrier and
the clutch cam. Install the retainers.
32. Install the 12 clutch rollers
and hold them in position with a
strong rubber band.
33. Rotate the roller cage coun-
terclockwise (from the rear) until
the rollers are off the cam surfaces.
 6-54 GROUP 6 MANUALSHIFTTRANSMISSIONS

is correctly engaged when a spring

KEEPSHIFT
PAWL BALK RING GEAR
FORK IN
load is apparent as the lever
... GROOVE is pushed forward.
40. Install the retaining pin in the
overdrive housing to hold the control
shaft in place.
...
41. If the overdrive housing bush-
ing and seal are to be replaced, use
the same tools which are used on
conventional transmissions.

~-~~~- "ii[;i~;,\"" ' --

INSTALLWITH MACHINED
RECESSIN THIS POSITION CIOI3-A
FIG. 19-Plate and Trough
Installed
The rubber band will hold them
there.
34. Slide the overdrive output
shaft carefully over the clutch roll-
ers. The rubber band will not affect
operation of the overdrive.
35. Align the shift rail spring with
the holes in the overdrive housing.
36. Place a new gasket on the
overdrive adapter, and hold it in
nlace with 2asket sealer (Pi2. 21).
SHIFT RAIL SUN GEAR
-
"Co'.' C1014-A
FIG. 20-Sun Gear and Shift
Rail Installation
37. Install the overdrive housing
over the overdrive output shaft and
shift rail.
38. If the overdrive output shaft
bearing snap ring does not drop into
its groove when the housing is seated
squarely on the adapter, pry the
overdrive output shaft bearing to-
ward the rear, working through the
snap ring hole. Install the overdrive
housing attaching bolts.
39. Engage the overdrive shaft le-
ver by pushin~ it inward. The lever
42. Thread the governor into the
overdrive housing.
43. Position the solenoid in the
adapter. Rotate the solenoid 1/4 turn
from normal position so that the
half ball on the solenoid stem can
engage the pawl.
If the solenoid stem is properly en-
gaged, the solenoid cannot be re-
moved from the overdrive in its nor-
mal position. Any attempt to pull it
out will merely compress the engag-
ing spring in the solenoid. Install the
two solenoid attaching screws.
44. Install the drain plugs in the
transmission case and in the over-
drive housing. Make sure the mag-
netic plugs are installed in the bot-
tnm of the case.

~
 SEA.L

...
OVERDRIVEMAINSHAFT
AND GEAR
C1580-A

FIG. 21-0verdrive Unit

Disassembled
6-56

SPECIFICAliONS

THREE-SPEED TRANSMISSION-2.77
GEAR RATIOS
-
Gear
- -
Transmission Engine First Second Thiird
CarUsage Model C.I.O. Speed Speed Speled Reverse
Falcon HED-BH I70-IV 3.29 1.83 1~
-.-J:1 4.46
FalconRanchero HED-BJ I7D-IV 3.29 1.83 1.00:1 4.46
Mustang HED.BG 20D-IV 2.76 1.69 1.00:1 3.74
Falcon,Comet,
Fairlane HED-BF 200-1V 2.76 1.69 1.00:1 3.74

CLEARANCES LUBRICANT REFILL CAPACITIES

Application Pints (Approximate)

All Models 2

TORQUE LIMITS

LUBRICANTS & SEALERS

THREE-SPEEDTRANSMISSION-3.03
GEAR RATIOS
Ratio
-
Transmission Engine First Second Third
Car Usage Model C.I.D. Speed Reverse
Speed Speed
Fairlane HEF.GX 200-IV H.D. 2.99 1.75 1.00:1 3.17

Fairlaneand
- 289-2V-4V
- - - -
Comet
HEG-W 390-2V-4V 2.42 1.61 1.00:1 2.33
FalconandComet
HEG-X
HEF-CX
- - - -
289.2V-4V 2.99 1.75 1.00:1 3.17
Mustanl! HEF-CW 289.2V-4V 2.99 1.75 1.00:1 3.17
THREE-SPEED TRANSMISSION-3.03 (Continued)
CLEARANCES LUBRICANT REFILL CAPACITIES

Description Inches

CountershaftGearEndPlay 0.004-0.018
ReverseIdler GearEndPlay 0.004-0.018
TORQUE LIMITS

Description Ft-lbs.

LUBRICANTS & SEALERS

Input Shaft BearingRetainerto TransmissionCase 30-36

Application Material ,

ExtensionHousingto TransmissionCase ! 42-50

Mild EPGearOil Access Cover to Transmission Case ; 14-19

Transmission C3RZ19547-B
Main Shaft Roller Bearing LubeGrease
I GearShiftControlLeversto CamandShaft ; 10-15
10.18
18.23

M-4659 [ ShiftForkto ShiftRail

CountershaftGearRollerBearing
I Filler Plugto Case
Sealer
Bolts and Gaskets M-4G91-B Drain Plug to Case 20-30

SteeringColumn Lithium BaseGrease Transmissionto FlywheelHousing 37.42

LowerPlate (No Polyethylene)

C3VY-19586-A DetentSet Screw(Special)
*Flush to 0.020 inchesbelowtop of case.

DAGENHAM FOUR-SPEEDTRANSMISSION
GEAR RATIOS
-
Ratios
Transmission Vehicle Engine
- - - -
Model Usage C.I.D. 1st 2nd 3rd 4th Rev.

HEJ-E Mustang 200-IV 3.16 2.21 1.41 1.1 3.34

CLEARANCES TORQUES

Description Inches Description Ft.-Lbs.

CountershaftGearEndPlay 0.008-0.022 ExtensionHousingto CaseBolts 40-45

FlywheelHousingto CaseBolts 40-45
FlywheelHousingto EngineBolts 23-28
, Input Shaft BearingRetainerBolts
12-15
Output Shaft BearingNut 20-25
Shift HousingRetainingBolts 12-15
Shift Leverto LinkageCapScrews 15-20
Shift RodLock Nuts 15-20

FORD FOUR-SPEED TRANSMISSION

GEAR RATIOS
-
Ratios
Engine - -
Trans.Model VehicleUsage Displacement 1st 2nd 3rd 4th Rev.

HEH-BV Falcon, 289.2V 2.78 1.93 1.36 Direct 2.78

Comet,Fairlane 289.2V & 4V
-
- - - - -
HEHoAR Fairlane 390-2V& 4V 2.32 1.69 1.29 Direct 2.32
Comet
- - - - -
HEH-BW Mustang ;: 289-4V 2.78 1.93 1.36 Direct 2.78

HEH-BX Mustang 289-4VH.P. 2.32 1.69 1.29 Direct 2.32

FORD FOUR-SPEED TRANSMISSION (Continued)
TORQUES LUBRICANT REFILL CAPACITIES
Description Part Name Ft.Lbs. Application Pints (Approximate)
Input Shaft Bearing Bolt- 5/16-18 x 3f4Hex Head 19-25 All Models 4
Retainerto Trans-
missionCase
-
ExtensionHousingto Bolt-7/16-14 X IV4 Hex HeadI 42-50
TransmissionCase
-
AccessCoverto Screw-15/16-18 x 0/8HexHead 14-19
TransmissionCase Screw-5/16-18 x 1 Hex Head
-
GearShift Lever Nut-3fs-24Hex 18-23
to Camand Shaft
-
Shift Fork to Shift x .92 Set
Screw-5/ 16-24 10-18
Rail locking --
Filler Plugto Case Plug-¥2-14 10-20
DrainPlugto Case Plug-¥2-14(Magnetic) 20-30
DetentSet Screw Screw-3fa-16x .88 Set flush to
(Special) 0.020"
below
surface CLEARANCES
Third and FourthShift Bolt-%-16 x .38HexHead 10-18
Rail DetentBolt
-
FlywheelHousing --., I
to Bolts Bolt-7/
Transmission 16,14
'00 -. 37-42

OVERDRIVE
GEAR RATIOS
-
Ratios
Trans. Trans.Assy. Vehicle Engine -
Model Part Number Usage Displacement 1st 2nd 3rd Rev. 0.0.
HEK-X C50R-7003-N Fairlane 289-2V 2.80 1.69 Direct 3.80 .70

TORQUE SPECIFICATIONS LUBRICANTS & SEALERS

Description Ft.Lbs.

-
Input Shaft Bearing Retainerto TransmissionCase Bolt
- : 12-15
Transmissionto FlywheelHousingBolts ~
I GearshiftHousingto TransmissionCaseBolts rl2:i5
I
TransmissionExtensionHousingto CaseBolts or Nuts 42-50
Gearshift Control Levers to Cam and Shaft 12-15
Assembly Nuts
Overdrive Assembly to Transmission Case Nuts
-
37-42
EngineRearSupportto ExtensionHousingBolts 35-40
Filler Plug to Case 10-20
Drain Plug to Case(Magnetic) 20-30

TRANSMISSION COMPONENT END PLAY

Component EndPlay
LUBRICANT REFILL CAPACITIES
Countershaft
Gearto Case 0.004-0.018
CamRampto Interlock Shift Sleeve- 0.001-0.007
Clearance
 PART 6-7-SPECIFICATIONS 6-59

SERVICE TOOLS SERVICE TOOLS (Continued)